MyBinding Gbc F60H Manual User

2013-06-04

User Manual: MyBinding Gbc-F60H-Manual

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GBC F-60H

Roll Laminator

Instruction Manual

WARNNG

ACHTUN

MS N AR

PRO-TECH

F-60 H

GBC Pro - Tech

4151 Anderson Road

DeForest, WI 53532

Revision : A Ph: ( 608 ) 246 - 8844

Fx: ( 608 ) 246 - 8645

FALCON 60 H

OPERATION & MAINTENANCE

MANUAL

Do not duplicate without written permission.

Part number : 930 - 063

Read me fileF 60 H Operation and Maintenance Manual

Read Me File . . . . . . . . .

The information in this publication is provided for reference and is believed to be accu-

rate 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 merchantabil-

ity 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

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served. The information contained in this publication is proprietary and may not be repro-

duced, stored, transmitted, or transferred, in whole or in part, in any form without the prior and

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Read me file F 60 H Operation and Maintenance Manual

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Fax Correspondence

Fax number : ( 608 ) 246 - 8645 Date :

To : Technical Coordinator at GBC Protech

4151 Anderson Road

DeForest, WI 53532

From :

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Address :

Phone number : ( ) Fax number : ( )

Re : F 60 H Operations and Maintenance Manual ( 930063A )

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Page I

Table of ContentsF 60 H Operation and Maintenance Manual

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 II

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 III

Table of ContentsF 60 H Operation and Maintenance Manual

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 IV

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 V

Table of ContentsF 60 H Operation and Maintenance Manual

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

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

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

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

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

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

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

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

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

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

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

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

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

Page VI

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

Safety

Page 1 - 1

F 60 H Operation and Maintenance Manual

1.0 Safety

CAUTION

Do not attempt to operate your

Falcon 60 H laminator until you

have read this section carefully!

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.

1.1 Symbols

INFORMATION

Indicates helpful information that should be

considered before, during, or after an

action, step or procedure is given.

CAUTION

Indicates a potentially hazardous situation

which, if not avoided, could result in minor

or moderate injury, or alerts against unsafe

practices or alerts against actions which

could damage the product.

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 - 2

Safety F 60 H Operation and Maintenance Manual

1.2 Safety precautions

The Falcon 60 H laminator has been designed

with safety as a primary consideration; however, you must

become thoroughly familiar with the controls, proper

operation, proper service procedures and safety features

of the laminator before using or servicing the unit.

The manual main roller lift mechanism used to

provide downward pressure on the upper main roller is

capable of producing forces greater than 400 pounds.

This force is applied to any object presented in the opening

( called the nip ) between the two rollers.

Use care in lowering the upper laminating roller

and know how to react quickly in an emergency. The

main laminator roll up / down control is located on the

right side of the machine within the front. Before turning

the crank handle to set the GAP down, ensure that nothing

is in the nip area.

WARNING

Keep hands and fingers clear of the

laminator roller nip when adjusting nip.

You can be CRUSHED or BURNED!

In addition, the main laminating rollers of the

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

DANGER

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;

Qualified;

• Any engineer that has experience with electrical

and mechanical design of lamination equipment. The

engineers should be fully aware of all aspects of safety

with regards to lamination equipment.

• Any commissioning or service engineer must be

of competent nature, trained and qualified to GBC Films

Group standards to fulfill that job. This person will have

completed and passed the full service training course from

GBC Pro-Tech.

• Any GBC Technician, GBC Specialist, and / or

GBC Films Group Technician that has been through the

GBC Pro-Tech service training course.

Safety

Page 1 - 3

F 60 H Operation and Maintenance Manual

1.3 Safety features

The laminator is equipped with four emergency

stops ( E-STOP ). Two are located at the front of the

cabinets and two are at the rear of the cabinets.

E-STOP

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

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

the laminator.

INFORMATION

The machine will only operate if all four

E-STOPS are in the unlatched position.

To continue operation, all E-STOPs must be in

the unlatched position. To reset, twist the E-STOP 1/4

turn counter clockwise.

Press RESET located on the control side cabinet

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

off.

POWER

Reset

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.

RO T CH

F 60 H

PHOTO-EYE

Page 1 - 4

Safety F 60 H Operation and Maintenance Manual

WARNING

The Falcon 60 H Laminator is a large and

heavy piece of equipment. It is necessary to

employ LICENSED RIGGERS ONLY to

move the laminator. The laminator is not

designed to be tipped up or sideways in any

way. Such action disturbs the exact

alignment of the rolling parts of the machine

and requires extensive realignment. You can

be crushed or seriously injured.

INFORMATION

ALL SHIPMENTS ARE EX-WORKS.

At our

dock, title passes to the buyer. Please review

your insurance coverage prior to shipment,

as you are responsible for all subsequent

freight charges and risks.

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.

WARNING

The unpacking process requires at least two

people. You can be severely injured, crushed

or cause damage to the laminator.

1.4 Installation

The following symbols are positioned at various

points in Section 4 Installation.

CAUTION

Failure to follow the pre-installation check

list can result in damage to the laminator.

WARNING

The operating environment must be free of

dust, flammable liquids and vapors. You can

be injured by inhaling chemical vapors.

WARNING

Vapor build up or stored flammable

liquids can cause a fire. Excessive

dust can damage the laminator.

CAUTION

Do not locate the Falcon 60 H where air is

blowing directly on the machine. The air

flow can cool the rolls unevenly and result

in poor output quality.

Safety

Page 1 - 5

F 60 H Operation and Maintenance Manual

INFORMATION

Depending on the destination and customer

preference, your machine may be shipped in

various ways. The laminator may arrive

shrink wrapped or in a plywood crate on a

skid. Please follow the unpacking procedure

that pertains to your method of shipment.

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.

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.

INFORMATION

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.

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 - 6

Safety F 60 H Operation and Maintenance Manual

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.

INFORMATION

CAUTION

Do not move the leveling nut when securing

the inside nut to the cabinet.

You will need the control side cabinet cover

off to connect the electrical power.

INFORMATION

ELECTRICAL

SHOCK

Only a qualified electrician should connect

power to the laminator. You can be severely

shocked, electrocuted or cause a fire if

power is improperly applied.

WARNING

Follow the correct wiring diagram when

supplying power to the laminator. If

improperly connected, you can be seriously

injured or cause damage to the laminator.

WARNING

Do not wear ties, loose fit clothing or

dangling jewelry while operating or

servicing the laminator. These items can get

caught in the nip and choke you or you can

be crushed or burned.

WARNING

If a safety feature is not working

properly, contact your local service

representative immediately.

CAUTION

Do not use a hard substrate or a substrate

with sharp edges. You may cause damage to

the laminating rollers!

Safety

Page 1 - 7

F 60 H Operation and Maintenance Manual

1.5 Operations

The following symbols are positioned at various

points in Section 5 Operations.

WARNING

Do not 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

The machine will only operate if all

four emergency stops are unlatched and

RESET has been pressed.

It is unsafe to sheet feed without the

pressure plate properly placed on

the front feed table.

WARNING

Keep hands and fingers clear of the

laminator roller nip when changing GAP.

You can be CRUSHED or BURNED!

WARNING

When the laminator rollers are in

motion, keep hands and fingers

away from the nip of the rollers.

You may be CRUSHED or BURNED!

WARNING

When operating the laminator using the

footswitch, keep hands and fingers

away from the nip of the rollers.

You may be CRUSHED or BURNED!

WARNING

Do not operate the laminator, except

during web set up, without the front

and rear feed tables in position.

Ensure the roll of laminate is loaded

properly on the unwind shaft.

Exposed adhesive should be facing

away from the rollers.

This will prevent hours of roll cleaning!

CAUTION

INFORMATION

The Poly-in/ Poly-out diagrams refer to the

upper rolls of film only. The mount adhesive

and craft papers are for reference only.

Page 1 - 8

Safety F 60 H Operation and Maintenance Manual

Never leave the unwind shaft out of the

unwind support saddle unless loading

or unloading film.

WARNING

When using two rolls on the machine,

ensure the film widths are identical.

Exposed adhesive can cause complications.

CAUTION

Never use an open blade near the laminating

rollers. You may cut the rollers or your self.

CAUTION

Always use the minimum amount

of brake for the job.

INFORMATION

If more brake is needed, add an O-ring

to the brake side of the rewind.

INFORMATION

CAUTION

Excess pressure can damage the laminating

rollers. Always use the minimum roll

pressure necessary to complete the task.

CAUTION

Objects other than media, film or approved

substrates, will cause irreparable damage

to the rollers if caught in the nip.

CAUTION

Sharp edges on a substrate

should be filed smooth.

Sharp edges can CUT the rollers!

Excessive pressure will cause the

substrate to bow or flatten.

INFORMATION

Density of the substrate will determine the

amount of pressure you may use.

INFORMATION

Safety

Page 1 - 9

F 60 H Operation and Maintenance Manual

1.6 Applications

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.

INFORMATION

Use film brake tension to control the

separation point of the release liner.

Speeds and temperatures will affect the

bond strength of Lo-Melt adhesives.

INFORMATION

The mount adhesive must not exceed 1 in.

the width of the substrate. If it does, you

will experience complications with this

application.

INFORMATION

Excessive pressure will cause the

substrate to bow or flatten.

INFORMATION

Excessive brake tension may cause the

image to curl. Always use the minimum

amount of brake for the job.

INFORMATION

CAUTION

Excess pressure can damage the laminating

rollers. Always use the minimum roll

pressure necessary to complete the task.

Never stop the laminator when an image is

within the nip of the rollers.

INFORMATION

Laminates and papers should always be

stored in a controlled enviroment.

INFORMATION

Page 1 - 10

Safety F 60 H Operation and Maintenance Manual

1.7 Troubleshooting

The following symbols are positioned at various

points in Section 7 Troubleshooting.

WARNING

Do not wear ties, loose fitting clothing or

dangling jewelry while operating or

servicing the laminator. These items can get

caught in the nip and choke you or you can

be crushed or burned.

INFORMATION

For optimal temperature settings of

various laminates, contact your

supplier or sales representative.

1.8 Maintenance

The following symbols are positioned at various

points in Section 8 Maintenance.

WARNING

Do not wear ties, loose fit clothing or

dangling jewelry while operating or

servicing the laminator. These items can get

caught in the nip and choke you or you can

be crushed or burned.

INFORMATION

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.

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.

Safety

Page 1 - 11

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!

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.

WARNING

When operating the laminator using the

footswitch, keep hands and fingers

away from the nip of the rollers.

You may be CRUSHED or BURNED!

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.

Remove ALL power to the laminator before

removing any cabinet covers.

You may be shocked or electrocuted!

WARNING

Always practice lock out/ tag out procedures

when performing any type of service or

maintenance work on the machine.

INFORMATION

The motor controls the tension of the both

chains. If one chain is still too loose,

a half link may be removed.

Page 1 - 12

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.

DANGER

HAZARDOUS

VOLTAGE

GEFAHR

To be serviced only

by trained and

authorized personnel.

Lockout power before

servicing

Hazardous Voltage: Do not open these cabinets. This

machine is to be serviced only by trained and authorized

personnel.

WARNING

ACHTUNG

MISE EN GARDE

Crush and burn

hazard. Sta

clear

of movin

rollers.

Stop machine and

raise roll before

cleanin

Roller Pinch Point: Keep hands and fingers away.

You may be crushed and/ or burned.

WARNING

ACHTUNG

MISE EN GARDE

Moving parts can

crush and cut.

Moving Parts: Keep hands and fingers away. You

may be crushed and/ or cut.

WARNING

ACHTUNG

MISE EN GARDE

Carefully read Operator's

Manual before handling

this machine. Observe

instructions and safety

rules when operating.

Read Manual: Read and understand the Operations

Manual before attempting to run this machine.

Safety

Page 1 - 13

F 60 H Operation and Maintenance Manual

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.

Refer to Figure 1.9.1 Label Placement illustrates

the location of each of these labels.

Page 1 - 14

Safety F 60 H Operation and Maintenance Manual

Figure 1.9.1 Safety label locations

ARNN

AH U

MS N

PRO-TECH

F-60 H

WARNING

ACHTUNG

MISE EN GARDE

Crush and burn

hazard. Stay clear

of moving rollers.

Stop machine and

raise roll before

cleaning.

WARNING

ACHTUNG

MISE EN GARDE

Carefully read operator's

Manual before handling

this machine. Observe

instructions and safety

rules when operating.

(Inside cabinet)

WARNING

ACHTUNG

MISE EN GARDE

Moving parts can

cruch and cut.

(Inside cabinet)

DANGER

GEFAHR

HAZARDOUS

VOLTAGE

To be serviced only

by trained and

authorized personnel.

Lockout power before

servicing

Page 2 - 1

WarrantyF 60 H Operation and Maintenance Manual

2.0 Warranty

GBC Films Group warrants the equipment sold

is free from defects in material and workmanship for a

period of one ( 1 ) year parts ( excludes normal wear

items ) and 90 days labor from the date of installation.

This warranty is the only warranty made by GBC Films

Group and cannot be modified or amended.

GBC Films Group’s sole and exclusive

liability and the customer’s sole and exclusive

remedy under this warranty shall be, at GBC Films

Group’s option, to repair or replace any such

defective part or product. These remedies are only

available if GBC Films Group’s examination of the

product discloses to GBC Films Group’s satisfaction

that such defects actually exist and were not caused

by misuse, neglect, attempt to repair, unauthorized

alteration or modification, incorrect line voltage, fire,

accident, flood, or other hazard.

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.

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 - 2

Warranty F 60 H Operation and Maintenance Manual

Qualified

• Any engineer that has experience with electrical

and mechanical design of lamination equipment. The

engineers should be fully aware of all aspects of safety

with regards to lamination equipment.

• Any commissioning or service engineer must be

of competent nature, trained and qualified to GBC Films

Group standards to fulfill that job. This person will have

completed and passed the full service training course from

GBC Pro-Tech.

• Any GBC Technician, GBC Specialist, and / or

GBC Films Group Technician that has been through the

GBC Pro-Tech service training course.

Page 3 - 1

SpecificationsF 60 H Operation and Maintenance Manual

3.0 Specifications

Specifications provide all of the technical data for

the Falcon 60 H Laminator.

3.1 General

Description:

Features:

Applications:

• 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.

• 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)

• Single sided lamination

• Mounting

• Decaling

• Low melt film

Page 3 - 2

Specifications F 60 H Operation and Maintenance Manual

3.2 Consumable

Film types:

Film diameters:

Core size:

Film widths:

Paper widths:

Mounting thickness:

Safety:

• Pressure sensitive laminates

• Pressure sensitive adhesives

• Low melt laminates

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

• 3 in. core standard ( 7.62 cm )

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

( 5.72 cm )

• 62 in. Pressure sensitive ( 162.6 cm )

• 60 in. Low Melt ( 157.8 cm )

• 62 in. maximum paper width ( 157.8 cm )

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

• Designed to UL safety standards

Page 3 - 3

SpecificationsF 60 H Operation and Maintenance Manual

3.3 Function

Speed:

Motor:

Heating capabilities:

Controls:

Roll design:

• 0 - 16 ft / min ( 0 - 4.6 m / min )

• 2-1/4 horse power drive motor

• Bi-directional D.C. motor

• 68oF - 200oF ( 20oC - 93oC )

• Front control panel

• Footswitch

• High release silicone rollers

Page 3 - 4

Specifications F 60 H Operation and Maintenance Manual

3.4 Electrical

United Statesand Canada:

B.T.U. output:

Heater wattages:

Amperage draw:

D/C voltage used:

A/C voltage used:

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

• 18,520 B.T.U. / hour

• 5429 watts per heater @ 240 vac

• No heat, motor only : 1 - 3 amps

• Top heat and motor : 25 - 30 amps

• 24 vdc

• 230~ 240 vac ( minimum )

Page 3 - 5

SpecificationsF 60 H Operation and Maintenance Manual

3.5 Dimensions

Weight:

Uncrated:

Crated:

Dimensions

Uncrated:

Crated

Nip Height:

• 1350 lbs. ( 612 kg. )

• 1625 lbs. ( 737 kg. )

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

( 203 cm (H) x 98 cm (W) x 145 cm (L) )

Refer to Figure 3.5.1 Dimensions

• 90 in. (L) x 44 in. (W) x 68 in. (H)

( 229 cm (H) x 112 cm (W) x 173 cm (L) )

• 38 in. ( 96.5 cm )

Page 3 - 6

Specifications F 60 H Operation and Maintenance Manual

Figure 3.5.1 Dimensions

WARNING

ACHTUNG

MS N AR

PRO-TECH

F-60 H

57 in.

( 145 cm )

80 in.

( 203 cm )

38.5 in.

( 98 cm )

Page 4 - 1

InstallationF 60 H Operation and Maintenance Manual

Is the environment appropriate for the laminator?

The laminator requires a clean, dust and vapor

free environment to operate properly. Do not

locate it where there is air blowing directly on the

machine.

Have you contacted a certified electrician to both

wire the laminator and ensure that adequate power

is being supplied, having the appropriate capacity,

over current protection and safety lockouts are

available?

WARNING

The operating environment must be free of

dust, flammable liquids and vapors. You can

be injured by inhaling chemical vapors.

WARNING

Vapor build up or stored flammable

liquids can cause a fire. Excessive

dust can damage the laminator.

CAUTION

Do not locate the Falcon 60 H where air is

blowing directly on the machine. The air

flow can cool the rolls unevenly and result

in poor output quality.

4.0 Installation

GBC Films Group is committed to a program of

ongoing product improvement. As a result, we are

providing these instructions so you can insure that your

new Falcon 60 H Laminator is properly and securely

unpacked, moved, and installed. Installation should be

performed by a qualified technician.

Before a Falcon 60 H Laminator can be installed,

there are a few requirements that must be met. Make

certain that each of the requirements listed in the following

pre-installation checklist are met before beginning

installation.

CAUTION

Failure to follow the pre-installation check

list can result in damage to the laminator.

4.1 Pre-installation

Are doorways and hallways wide enough for the

laminator to be moved to the installation site?

Is there ample room for the laminator?

A work area must be established that allows for

operation in both the front and rear of the

laminator and provides space for efficient material

flow. Figure 4.1.1 illustrates a typical machine

area layout.

Page 4 - 2

Installation F 60 H Operation and Maintenance Manual

The Falcon 60 H requires single phase, 230 to

240 vac, 50/ 60 Hz, 40 amp service. No other

type of connection is permitted.

WARNING

The Falcon 60 H Laminator is a large and

heavy piece of equipment. It is necessary to

employ LICENSED RIGGERS ONLY to

move the laminator. The laminator is not

designed to be tipped up or sideways in any

way. Such action disturbs the exact

alignment of the rolling parts of the machine

and requires extensive realignment. You can

be crushed or seriously injured.

For instructions on how to connect power,

proceed to 4.9 Connecting power in this section.

Page 4 - 3

InstallationF 60 H Operation and Maintenance Manual

Figure 4.1.1 Suggested Floor Layout

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

Work table on wheels

Table height

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

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

Work table on wheels

Table height

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

3 ft. ( 1 m )

13' ( 4 m)

20 ft.

( 6 m )

78 in.

( 2 m )

8.2 ft.

( 2.57 m )

38.5"

( .98 m )

8.2 ft.

( 2.57m )

Front operating position

Electrical

supply

Page 4 - 4

Installation F 60 H Operation and Maintenance Manual

4.2 Know your machine

Before performing any procedure within this

manual, it is recommended that you take time to know

the parts of your new machine.

Figure 4.2.1 The laminator

Front

Rear

Control side

( Right )

Drive side

( Left )

PRO TECH

F-60 H

Figure 4.2.2 Safety and controls

PRO-TECH

F-60 H

Control panel

Foot switch

Main roller lift

Upper unwind brake

Lower unwind brake

Core grip

E-stop

Core support

Rewind drive

Figure 4.2.3 Idlers and unwinds

PRO TECH

F-60 H

Upper unwind

Lower Unwind

Front table idler

Rear table idler

Web idler

Tie bars

Figure 4.2.4 Misc.

Main rollers

Front table

Rear table

Castors

Unwind saddle

Photo-eye

Run/ Stop

PR -TECH

F-60 H

Figure 4.2.5 Power

POWER

Reset

On/ Off

Page 4 - 5

InstallationF 60 H Operation and Maintenance Manual

4.3 Unpacking

INFORMATION

ALL SHIPMENTS ARE EX-WORKS.

At our

dock, title passes to the buyer. Please review

your insurance coverage prior to shipment,

as you are responsible for all subsequent

freight charges and risks.

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.

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.

With regards to your shipping methods, use one

of the following procedure described to safely and

properly unwrap / uncrate your laminator.

4.4 Shrink Wrapped

a) Inspect the machine for any obvious shipping

damages upon receipt. Report any damage to

your carrier.

b) Carefully unwrap the shrink wrap from around

the laminator.

CAUTION

Do not use a knife or other sharp object to

remove the shrink wrap from around the

laminator. You can cause irreparable

damage to the rollers.

c) Carefully wheel your Falcon 60 H Laminator

with a second person to the installation site.

WARNING

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 - 6

Installation F 60 H Operation and Maintenance Manual

4.5 Crated

WARNING

The Falcon 60 H Laminator is a large and

heavy piece of equipment. It is necessary to

employ LICENSED RIGGERS ONLY to

move the laminator. The laminator is not

designed to be tipped up or sideways in any

way. Such action disturbs the exact

alignment of the rolling parts of the machine

and requires extensive realignment. You can

be crushed or seriously injured.

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.

INFORMATION

Tools required

• # 2 Phillips head screwdriver

• 7/8” open end wrench or adjustable wrench

• Crow bar

• A second person

To uncrate the laminator

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

in the order shown in Figure 4.5.1

CAUTION

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

can damage the laminator.

INFORMATION

Do not put packing screws on the floor.

They can cause problems when trying to roll

the laminator into position or you can

become injured if stepped on.

CAUTION

A second person must support the side

labeled 5 in Figure 4.5.1 It can fall and

damage the laminator or cause harm to you

and others.

Page 4 - 7

InstallationF 60 H Operation and Maintenance Manual

Figure 4.5.1 Disassembling of the crate

R E

F-60 H

Removing the shrink wrap

a) Gently unwrap the shrink wrap from around the

laminator.

CAUTION

Do not use a knife or other sharp object to

remove the shrink wrap from around the

laminator. You can cause irreparable

damage to the rollers.

b) Move all packing materials to a safe distance.

Moving the laminator

a) Have the laminator rolled off the skid and placed

on the floor by licensed riggers. The ramps

included with the laminator can be secured utilizing

screws removed from the disassembled crate.

Figure 4.5.2 illustrates positioning of the ramps.

WARNING

Do not attempt to use the ramps if they are

not secured to the pallet. Ensure the pallet is

on a flat even surface before attempting to

roll the machine off.

Figure 4.5.2 Positioning of the ramps

b) Remove any plastic strapping and/or packing

paper taped to the rollers.

Page 4 - 8

Installation F 60 H Operation and Maintenance Manual

4.6 Accessory pack

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

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.

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.

INFORMATION

Page 4 - 9

InstallationF 60 H Operation and Maintenance Manual

4.7 Installing levelers

Leveling of the machine is a customer option. If

you choose not to level the laminator and you encounter

output problems, please level the machine and try your

application again before calling for technical support.

Tools required

• ( 2 ) 3/4” open end wrenches

• Four leveling pads

( from the accessory pack )

a) Verify that the laminator has sufficient room

around it to load film, walk around and to be

serviced if necessary.

b) Place one leveling pad on each of the four

leveling bolts on the laminator.

Leveling pads

Jam nuts

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

jam nut against the leveling pad.

4.8 Leveling

Leveling of the laminator is very important in the

way the machine performs. Leveling is crucial to the tram

( tracking ) of the materials through the machine.

Tools required

• ( 2 ) 3/4 in. open end wrenches

• 1/8 in. allen wrench

• Level

• A second person

a) 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.

2) Remove the seven screws along the

top and sides of the cover.

PRO-TECH

F-60 H

Page 4 - 10

Installation F 60 H Operation and Maintenance Manual

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

cabinet.

PRO-TECH

F-60 H

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.

PRO TECH

F-60 H

h) Level the laminator from drive side to control

side by turning the leveling nut clockwise to

raise or counter clockwise to lower.

b) Loosen the nut on the inside of both cabinets

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

Inside nuts

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

cabinet.

PRO TECH

F-60 H

d) Level the control side from front to back by

turning the leveling nut clockwise to raise or

counter clockwise to lower.

Leveling nuts

Page 4 - 11

InstallationF 60 H Operation and Maintenance Manual

i) Verify that all three points are still leveled.

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

end wrench while you secure the inside nut to

the cabinet. Do this for both sides.

Inside nuts

CAUTION

Do not move the leveling nut when securing

the inside nut to the cabinet.

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

You will need the control side cabinet cover

off to connect the electrical power.

INFORMATION

4.9 Connecting power

ELECTRICAL

SHOCK

Only a qualified electrician should connect

power to the laminator. You can be severely

shocked, electrocuted or cause a fire if

power is improperly applied.

Tools required

• 1/8 in. allen wrench

• # 2 phillips head screw driver

• Multi meter

a) Ensure the power at the junction box is in the

OFF position.

b) Feed the power cable through the main power

strain relief from the accessory pack, then

through the hole provided below the circuit

breaker on/ off.

Line Terminal Block

Strain relief

Power cable

Page 4 - 12

Installation F 60 H Operation and Maintenance Manual

c) Connect the wires to the Line Terminal Block

(LTB) as illustrated below.

red wires blue wires

hot leg hot leg ground

WARNING

Follow the correct wiring diagram when

supplying power to the laminator. If

improperly connected, you can be seriously

injured or cause damage to the laminator.

d) Secure the main power strain relief to the

cabinet.

e) Turn the junction box power to the ON

position.

f) Verify line voltage with regards to the type of

power being supplied to the laminator at the line

terminal block.

hot leg

(A)

hot leg

(B)

ground

(C)

• (A) - (B) = 230 ~ 240 VAC

• (A) - (C) = 115 ~ 120 VAC

• (B) - (C) = 115 ~ 120 VAC

g) Replace the control side cabinet cover.

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

flipping the handle to the up position and press

reset.

POWER

Reset

On/ Off

Page 4 - 13

InstallationF 60 H Operation and Maintenance Manual

4.10 Safety check

The safety check will ensure that all safety devices

and interlocks are functioning properly.

This procedure describes how to check one

E-STOP and the PHOTO-EYE. Repeat the steps for

the remaining three E-STOPS. ALL SAFETY

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.

WARNING

If a safety feature is not working

properly, contact your local service

representative immediately.

Contacts:

GBC National Service: ( 800 ) 790 - 7787

My service rep:_____________________

E-STOPs

a) Turn MAIN POWER to ON .

POWER

Off

b) Press RESET. The power indicator on the front

control panel will be illuminated.

POWER

Reset

c) Press the motor direction to FORWARD.

(reverse) (forward)

Page 4 - 14

Installation F 60 H Operation and Maintenance Manual

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

4567

e) Press the motor engage/ disengage to ENGAGE.

(disengage) (engage)

f) Press the temperature on/off to ON.

(off) (on)

g) Press one of the four E-STOPs.

h) The bottom main roller stops turning, the power

indicator light goes out, the display on the

temperature controller unit goes out.

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

unlatch.

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

three E-STOPs.

PHOTO-EYE

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

board to 4 inches x 6 inches. ( 10 cm x 15 cm )

This piece will be referred to as the “finger board”.

CAUTION

Do not use a hard substrate or a substrate

with sharp edges. You may cause damge to

the laminating rollers.

Page 4 - 15

InstallationF 60 H Operation and Maintenance Manual

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

and remove the pressure plate from the front feed

table.

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

illuminated, press Reset.

POWER

Reset

d) Set the motor direction to FWD.

(reverse) (forward)

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

on the pressure display is illuminated ).

f) Press the motor engage/ disengage to ENGAGE.

(disengage) (engage)

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

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

control side.

finger board

h) The rollers should stop just before the finger

board can enter the roller nip.

i) Slide the finger board back away from the rollers

nip. Press the motor engage/ disengage to

ENGAGE.

(disengage) (engage)

Page 4 - 16

Installation F 60 H Operation and Maintenance Manual

j) If the finger board comes in contact with the

rollers while they are turning, contact your

service representative to adjust the PHOTO-

EYEs.

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

about center of the front feed table.

finger board

l) The rollers should stop just before the finger

board can enter the roller nip.

m) Slide the finger board back away from the rollers

nip. Press the motor engage/ disengage to

ENGAGE.

(disengage) (engage)

n) If the finger board comes in contact with the

rollers while they are turning, contact your

service representative to adjust the PHOTO-

EYEs.

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

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

control side.

finger board

p) The rollers should stop just before the finger

board can enter the roller nip.

q) Slide the finger board back away from the

rollers nip.

r) If the finger board comes in contact with the

rollers while they are turning, contact your

service representative to adjust the PHOTO-

EYEs.

s) Raise the main roller.

Page 5 - 1

Operations

F 60 H Operation and Maintenance Manual

5.0 Operations

In this section you will find information on how to

properly turn your Falcon 60 H Laminator on, learn

functions of the control panel, increase and decrease

temperature, properly load and unload film, use of the

unwind brake tensioning system, rewind brake tensioning,

how to manually set the nip for mounting, and foot switch

function.

The following general rules should always be

adhered while operating this machine.

WARNING

Do not wear ties, loose fit clothing or

dangling jewelry while operating or

servicing the laminator. These items can get

caught in the nip and choke you or you can

be crushed or burned.

INFORMATION

The machine will only operate if all

four emergency stops are unlatched and

RESET has been pressed.

It is unsafe to sheet feed without the

pressure plate properly placed on

the front feed table.

WARNING

When the laminator rollers are in

motion, keep hands and fingers

away from the nip of the rollers.

You may be CRUSHED or BURNED!

WARNING

Keep hands and fingers clear of the

laminator roller nip when changing GAP.

You can be CRUSHED or BURNED!

WARNING

When operating the laminator using the

footswitch, keep hands and fingers away

from the nip of the rollers.

You may be CRUSHED or BURNED!

WARNING

Do not operate the laminator, except

during web set up, without the front

and rear feed tables in position.

Page 5 - 2

Operations F 60 H Operation and Maintenance Manual

5.1 Power On/ Off

Power on

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

STOPs are in the unlatched position.

b) Turn the MAIN POWER to the up position.

POWER

Off

c) Press RESET located above the main power

on/off.

POWER

Reset

d) Power indicator on the control panel should be

illuminated at this time.

4 7

Power indicator light

Power off

a) Ensure the rollers are in the up position.

b) Turn the MAIN POWER to the down position.

POWER

Off

Page 5 - 3

Operations

F 60 H Operation and Maintenance Manual

5.2 Control panel

The operator control panel for the Falcon 60 H

Laminator is located to the right of the front operating

position. For an illustration of the complete front control

panel, please refer to Figure 5.2.1 Falcon 60 H. The

names and functions of these controls are as follows:

( 1 ) NIP PRESSURE DISPLAY: When pressure at

the nip of the rollers is applied, bars on the nip pressure

display are illuminated in increments of 5% up to 100%.

( 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.

(disengage) (engage)

( 3 ) FWD / REV: When pressed to the right, the motor

turns in a forward direction as illustrated by the image

above the switch. When pressed to the left, the motor

turns in a reverse direction.

(reverse) (forward)

( 4 ) SPEED DIAL: When turned clockwise, increases

the speed of the motor. Turning it counter clockwise will

decrease motor speed.

4567

( 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) (on)

Page 5 - 4

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.

CAL 3200

Figure 5.2.1 Front control panel

( 7 ) POWER INDICATOR: When illuminated

represents power to the laminator is supplied. If not

illuminated, power to the laminator has been removed via

an E-STOP, no RESET, circuit breaker is the off position

or line voltage has been removed.

4567

CAL 3200

Page 5 - 5

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

(72 is an example of room temperature )

To display the current set point value of the

temperature controller unit, press and hold the star key

located just to the left just below the temperature display.

When the star key is released, the temperature display

reverts to the current temperature of the upper roller.

CAL 3

Increase set point

a) Press and hold ✽ key while pressing ▲ key to

increase the set point temperature. Single presses

of the ▲ key increases the set point by increments

of one while holding the key down will increase

by increments of ones then tens.

CAL 3 0

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

point has been obtained.

Decrease set point

a) Press and hold ✽ key while pressing ▼ key to

decrease the set point temperature. The same

increments apply.

CAL 3

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

point has been obtained.

Page 5 - 6

Operations F 60 H Operation and Maintenance Manual

5.4 Load/ Unload film

Ensure the roll of laminate is loaded

properly on the unwind shaft.

Exposed adhesive should be facing

away from the rollers.

This will prevent hours of roll cleaning!

CAUTION

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

Lo-Melt

Poly - out

Mount

adhesive

Lo-Melt

film

Lo-Melt

Poly - in

Craft

paper

Lo-Melt

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.

INFORMATION

The Poly-in/ Poly-out diagrams refer to the

upper rolls of film only. The mount adhesive

and craft papers are for reference only.

Figure 5.4.2 PSA Poly-in/ Poly-out

PSA

Poly - out

Mount

adhesive

PSA

film

PSA

Poly - in

Craft

paper

PSA

film

Page 5 - 7

Operations

F 60 H Operation and Maintenance Manual

Load film

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

of the roll of film being used but remain inside the

core when the roll of film is positioned on the

unwind shaft.

Roll of film

Core chuck Core chuckCore support

b) Lift up on the clevis pin to the unwind shaft located

in the unwind support saddle.

Clevis pin

Unwind support saddle

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

roll of film completely on.

Never leave the unwind shaft out of the

unwind support saddle unless loading

or unloading film.

WARNING

d) Swing the unwind shaft completely back into the

unwind support saddle and push the clevis pin

down.

Clevis pin

Unwind support saddle

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

film on the laminating rollers.

( A )

( B )

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

( C ) ( C )

When using two rolls on the machine,

ensure the film widths are identical.

Exposed adhesive can cause complications.

CAUTION

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

lower unwind shaft.

Page 5 - 8

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.

Center

Align

Unload film

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

blade.

Never use an open blade near the laminating

rollers. You may cut the rollers or your self.

CAUTION

b) Lift up on the clevis pin to the unwind shaft located

in the unwind support saddle.

Clevis pin

Unwind support saddle

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

roll of film completely off.

When using two rolls on the machine,

ensure the film widths are identical.

Exposed adhesive can cause complications.

CAUTION

d) Swing the unwind shaft completely back into the

unwind support saddle and push the clevis pin

down.

Clevis pin

Unwind support saddle

Page 5 - 9

Operations

F 60 H Operation and Maintenance Manual

5.5 Unwind brake tension

The unwind brakes are uniquely designed to allow

you to change rolls of film without changing your current

brake setting. Brake tension may vary from roll to roll so

some adjustments may be required for optimal output.

Always use the minimum amount

of brake for the job.

INFORMATION

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

or the lower gray brake disc ( not shown )

clockwise to increase unwind brake tension.

Increase decrease

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

or the lower gray brake disc ( not shown )

counter clockwise to decrease unwind brake

tension.

5.6 Rewind brake tension

The rewind brake controls the tension of the

rewind tubes. Rewind brakes along with the unwind brakes

allow for precise control of the release liner in PSA films.

If your Falcon 60 H is equipped with the roll to roll option,

the rewind brakes are helpful as the finished product

rewind becomes heavier by adding more friction to the

rewind tube.

a) Turn the brake dial counter clockwise to

increase rewind brake tension.

If more brake is needed, add an O-ring

to the brake side of the rewind.

INFORMATION

Increase Decrease

b) Turn the brake dial clockwise to decrease

rewind brake tension.

Page 5 - 10

Operations F 60 H Operation and Maintenance Manual

5.7 Setting the nip

Setting the nip is made easy when it comes to

performing a mounting application. Pressure will vary with

regards to the types of substrate being used. An incorrect

nip setting can cause complications with output quality.

For safe nip setting, always adhere to the following

rules listed below.

WARNING

Keep hands and fingers clear of the

laminator roller nip when adjusting nip.

You can be CRUSHED or BURNED!

CAUTION

Excess pressure can damage the laminating

rollers. Always use the minimum roll

pressure necessary to complete the task.

CAUTION

Objects other than media, film or approved

substrates, will cause irreparable damage

to the rollers if caught in the nip.

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

and RESET has been pressed.

POWER

Reset

b) Set the motor direction to REV.

(reverse) (forward)

c) Set a comfortable speed for the application you

are performing.

4567

Page 5 - 11

Operations

F 60 H Operation and Maintenance Manual

CAUTION

Sharp edges on a substrate

should be filed smooth.

Sharp edges can CUT the rollers!

d) Position the substrate center of the feed table

between the two rollers.

PR -TECH

F-60 H

substrate

e) Lower the upper main roller until it makes

contact with the substrate. Lower enough to

apply sufficient pressure without crushing the

substrate.

Excessive pressure will cause the

substrate to bow or flatten.

INFORMATION

Sufficient Excessive

Density of the substrate will determine the

amount of pressure you may use.

INFORMATION

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 - 12

Operations F 60 H Operation and Maintenance Manual

5.8 Footswitch

WARNING

When operating the laminator using the

footswitch, keep hands and fingers

away from the nip of the rollers.

You may be CRUSHED or BURNED!

The footswitch operates differently based on the

motor direction setting.

Forward

a) Press the motor direction to FWD.

(reverse) (forward)

b) Set your speed dial to a comfortable operating

speed.

4567

WARNING

The variable speed footswitch over-rides

the PHOTO-EYE safety circuit !

c) When the footswitch is pressed, roller speed is

dependent on what you have selected on the

speed dial.

d) You may adjust speed while the footswitch is

depressed.

Reverse

a) Press the motor direction to REV.

b) Press on the footswitch. The footswitch speed is

limited to 1 foot per minute ( 30 cm/ minute )

regardless of motor speed dial setting..

Page 6 - 1

ApplicationsF 60 H Operation and Maintenance Manual

6.0 Applications

The Falcon 60 H can accommodate Poly-in or

Poly-out films. Poly-out means the adhesive is on the

outside of the roll.

The shiny side of clear film must contact the main

rollers with the dull sides ( adhesive side ) facing out. Use

caution when loading matte or de-luster film since both

sides appear dull.

The top and bottom rolls of laminating film must

be of the same width and be present simultaneously. If

performing a single sided lamination process, a craft paper

carrier or a substrate of the same width must be used in

place of the bottom laminate.

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.

6.1 Helpful hints

Pressure sensitive materials

In most cases, a little heat ( 120 oF / 49 oC ) helps

the adhesive in pressure sensitive films flow smoothly to

prevent what we call “silvering” in the laminate.

The release liner on pressure sensitive films should

separate just above the main roller.

Use film brake tension to control the

separation point of the release liner.

INFORMATION

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.

Speeds and temperatures will affect the

bond strength of Lo-Melt adhesives.

INFORMATION

Page 6 - 2 © April 2001 General Binding Corporation

Applications F 60 H Operation and Maintenance Manual

Mounting

Mounting on the Falcon 60 H is achieved from

the front operating position. Heat can also assist with

mounting, it follows the same hints as pressure sensitive

materials.

The mount adhesive must not exceed 1 in.

the width of the substrate. If it does, you

will experience complications with this

application.

INFORMATION

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. )

Excessive pressure will cause the

substrate to bow or flatten.

INFORMATION

Brake tension

Brake tension should always be minimal. Brake

tension should always be even from the top roll of film

to the lower roll of film. Never use excessive amount of

brake tension.

Excessive brake tension may cause the

image to curl. Always use the minimum

amount of brake for the job.

INFORMATION

General

CAUTION

Excess pressure can damage the laminating

rollers. Always use the minimum roll

pressure necessary to complete the task.

Never stop the laminator when an image is

within the nip of the rollers.

INFORMATION

Laminates and papers should always be

stored in a controlled enviroment.

INFORMATION

Page 6 - 3

ApplicationsF 60 H Operation and Maintenance Manual

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 o C

68 20

69 20.6

70 21.1

71 21.7

72 22.2

73 22.7

74 23.3

75 23.9

76 24.4

77 25

78 25.6

79 26.1

80 26.7

81 27.2

82 27.8

83 28.3

84 28.9

85 29.4

86 30

87 30.6

88 31.1

89 31.7

90 32.2

91 32.8

92 33.3

93 33.9

94 34.4

95 35

96 35.6

97 36.1

98 36.7

99 37.2

100 37.8

101 38.3

102 38.9

103 39.4

104 40

105 40.6

106 41.1

107 41.7

108 42.2

109 42.8

110 43.3

111 43.9

113 45

114 45.6

115 46.1

116 46.7

117 47.2

118 47.8

119 48.3

120 48.9

121 49.4

122 50

123 50.6

124 51.1

125 51.7

126 52.2

127 52.8

128 53.3

129 53.9

130 54.4

131 55

132 55.6

133 56.1

134 56.7

135 57.2

112 44.4

136 57.8

137 58.3

138 58.9

139 59.4

140 60

141 60.6

142 61.1

143 61.7

144 62.2

145 62.8

146 63.3

147 63.9

148 64.4

149 65

150 65.6

151 66.1

152 66.7

153 67.2

154 67.8

155 68.3

158 70

159 70.6

160 71.1

161 71.7

162 72.2

163 72.8

164 73.3

165 73.9

166 74.4

167 75

168 75.6

169 76.1

156 68.9

157 69.4

170 76.7

171 77.2

172 77.8

173 78.3

174 78.9

175 79.4

176 80

177 80.6

178 81.1

179 81.7

180 82.2

181 82.8

182 83.3

183 83.9

184 84.4

185 85

186 85.6

187 86.1

188 86.7

189 87.2

190 87.8

191 88.3

192 88.9

193 89.4

194 90

195 90.6

196 91.1

197 91.7

198 92.2

199 92.8

200 93.3

Page 6 - 4 © April 2001 General Binding Corporation

Applications F 60 H Operation and Maintenance Manual

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Page 6 - 5

ApplicationsF 60 H Operation and Maintenance Manual

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 prod-

uct 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 pro-

cess 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 per-

formance 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, web-

bing diagrams for related applications are aslo incleded.

Applications F 60 H Operation and Maintenance Manual

PROCESS CONTROL CHART

Materials -

Top material :

Bottom material :

Other material (s) :

CAL 3200

Motor Direction

Motor Speed

4567

Roller Pressure

Upper Roller Temperature

Heater

RANGE

Notes :

RANGE

Page 6 - 7

ApplicationsF 60 H Operation and Maintenance Manual

Diagram - Blank

Applications F 60 H Operation and Maintenance Manual

This page intentionally left blank.

Page 6 - 9

ApplicationsF 60 H Operation and Maintenance Manual

Diagram - Blank w/ roll to roll options

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

CAL 3200

Motor Direction

Motor Speed

4567

range

Roller Pressure

Upper Roller Temperature

Heater

RANGE

Notes : The roll of mount adhesive should not exceed the substrate by more than 1 in.

(2.5 cm). Speed will be determined by what is comfortable with the operator. Pressure

is dependent on the substrate. Do not crush the substrate. Use a leader board to start

the run and stop the run when the trailer board is in the nip of the rollers. Stopping on

a subtsrate will leave an impression on the board. Refer to helpful hints for pressure

sensitive materials and mounting.

RANGE

Page 6 - 11

ApplicationsF 60 H Operation and Maintenance Manual

Diagram - Pre-coating substrates

Roll of

mount

adhesive

Leader board

Substrate

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

CAL 3200

Motor Direction

Motor Speed

Roller Pressure

Upper Roller Temperature

Heater

RANGE

Notes: The image shoud not exceed the pre-coated board by more than 1 in. ( 2.5 cm ). If

the image is smaller than the precoated board, trim the board or pre-trim the release liner

around the image. Speed for mounting should be comfortable for the operator. Use the

footswitch for this application. Pressure will be dependent on the type of subtrate. No

heat is required for this application. Do not crush the substrate. Do not stop in the middle

of the run. Refer to helpful hints for mounting.

RANGE

4567

range

Page 6 - 13

ApplicationsF 60 H Operation and Maintenance Manual

Diagram - Mounting an image

Pre-coated

board

Liner

Image

Hold image here

Applications F 60 H Operation and Maintenance Manual

CAL 3200

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

4567

range

Roller Pressure

Upper Roller Temperature

Heater

RANGE

Notes: Speed should be comfortable for the operator. Pressure will vary depending on the

weight and width of the image and laminate. Heat is optional. Some will assist the flow of

the adhesive in pressure sensitive films. Refer to helpful hints for pressure sensitive films.

RANGE

Page 6 - 15

ApplicationsF 60 H Operation and Maintenance Manual

Diagram - PSA decaling

Image

Decal

Roll of

PSA film

Roll of

mount

adhesive

Release liner

Applications F 60 H Operation and Maintenance Manual

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Page 6 - 17

ApplicationsF 60 H Operation and Maintenance Manual

Roll of

PSA film

Roll of

mount

adhesive

Release liner

Roll of

prints

Rewind of decals

Diagram - PSA decaling w/ roll to roll options

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

CAL 3200

Motor Direction

Motor Speed

4567

range

Roller Pressure

Upper Roller Temperature

Heater

RANGE

Notes : Speed will be dependent on the activation of the Lo-Melt adhesive. If the output

appears cloudy or milky, reduce the speed. Pressure will vary depending on the weight

and width of the image and laminate. For thinner laminates, use the 180 oF ( 82 oC ) and

for thicker films, use the 200 oF ( 93 oC ).

RANGE

Page 6 - 19

ApplicationsF 60 H Operation and Maintenance Manual

Diagram - Lo-Melt decaling

Image

Decal

Roll of

Lo-Melt

film

Roll of

mount

adhesive

Applications F 60 H Operation and Maintenance Manual

This page intentionally left blank.

Page 6 - 21

ApplicationsF 60 H Operation and Maintenance Manual

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

Roll of

Lo-Melt

film

Roll of

mount

adhesive

Roll of

prints

Rewind of decals

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

CAL 3200

Motor Direction

Motor Speed

Roller Pressure

Upper Roller Temperature

Heater

RANGE

Notes: Speed for mounting should be comfortable for the operator. Use the footswitch

for this application. Pressure will be dependent on the type of subtrate. No heat is

required for this application. Do not crush the substrate. Do not stop in the middle of

the run. Refer to helpful hints for mounting.

RANGE

4567

range

Page 6 - 23

ApplicationsF 60 H Operation and Maintenance Manual

Diagram - Mounting a decal

Substrate

Liner

Decal

Hold decal here

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

CAL 3200

Motor Direction

Motor Speed

4567

range

Roller Pressure

Upper Roller Temperature

Heater

RANGE

Notes : The leader board and trailer board should be the same width as the pre-coated

board. The laminate should not exceed the pre-coated board by more than 1 in. ( 2.54 cm ).

Do not use excessive brake tension for this application. Pre-coated board is reusable

since the laminate does not bond with the release liner from the pressure sensitive

adhesive. Speed should be comfortable for the operator. Pressure will vary depending on

the type of substrate. Heat is optional. Some heat will assist the flow of adhesive. Refer to

helpful hints for pressure sensitive films.

RANGE

Page 6 - 25

ApplicationsF 60 H Operation and Maintenance Manual

Pre-coated

board

Roll of

PSA film

Release liner

Leader board

Image

Diagram - PSA single sided lamination

( sled method )

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

CAL 3200

Motor Direction

Motor Speed

4567

range

Roller Pressure

Upper Roller Temperature

Heater

RANGE

Notes: Top and bottom material should be of the same width. Do not use excessive brake

tension for this application. Speed should be comfortable for the operator. Pressure will

vary depending on the width and weight of the image and laminate. Heat is optional.

Some heat will assist the flow of adhesive. Refer to helpful hints for pressure sensitive

films.

RANGE

Page 6 - 27

ApplicationsF 60 H Operation and Maintenance Manual

Diagram - PSA single sided lamination

( craft paper method )

Image

Finished

product

Roll of

PSA film

Roll of

craft

paper

Release liner

Applications F 60 H Operation and Maintenance Manual

This page intentionally left blank.

Page 6 - 29

ApplicationsF 60 H Operation and Maintenance Manual

Diagram - PSA single sided lamination

( craft paper method w/ roll to roll option )

Roll of

PSA film

Roll of

craft

paper

Release liner

Roll of

prints

Rewind of

finished product

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

CAL 3200

Motor Direction

Motor Speed

4567

range

Roller Pressure

Upper Roller Temperature

Heater

RANGE

Notes : The laminate should not exceed the pre-mounted image by more than 3 in. (7.6 cm).

Speed will be determined by what is comfortable with the operator. Pressure is dependent

on the substrate. Do not crush the substrate. Use a leader board to start the process and

finish with a trailer board. Stopping on the image will aleave an impression on the board

or image. Heat is optional. Refer to helpful hints for pressure sensitive materials and

mountng.

RANGE

Page 6 - 31

ApplicationsF 60 H Operation and Maintenance Manual

Diagram - PSA over-lamination of a mounted image

Mounted image

Roll of

PSA film

Release liner

Leader board

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

CAL 3200

Motor Direction

Motor Speed

4567

range

Roller Pressure

Upper Roller Temperature

Heater

RANGE

Notes : The laminate should not exceed the pre-mounted image by more than 3 in. (7.6 cm).

Speed will be determined by what is comfortable with the operator. Pressure is dependent

on the substrate. Do not crush the substrate. Use a leader board to start the process and

finish with a trailer board. Stopping on the image will aleave an impression on the board

or image. Heat is dependent on the thickness of the film. Refer to helpful hints for Lo-Melt

films and mountng.

RANGE

Page 6 - 33

ApplicationsF 60 H Operation and Maintenance Manual

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

Mounted image

Roll of

Lo-Melt

film

Leader board

Applications F 60 H Operation and Maintenance Manual

This page intentionally left blank.

Page 7 - 1

TroubleshootingF 60 H Operation and Maintenance Manual

7.0 Troubleshooting

WARNING

Do not wear ties, loose fitting clothing or

dangling jewelry while operating or

servicing the laminator. These items can get

caught in the nip and choke you or you can

be crushed or burned.

As an operator, you can perform some simple

troubleshooting in attempt to correct your typical output

type problems. Use the easy to follow guide for assistance.

7.1 Wave problems

The following is a list of common output wave

problems you may encounter.

The arrow along the length of the output

represents the direction of feed ( travel ).

INFORMATION

For optimal temperature settings of

various laminates, contact your

supplier or sales representative.

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

Hints: • Check paper tension

• Check relative moisture content of the paper

Problem: D Waves in the laminate

Hints: • Check the roll pressure

• Check the main roll nip settings

Page 7 - 2

Troubleshooting F 60 H Operation and Maintenance Manual

Problem: Straight waves in the output

Hints: • Check operational settings for materials

being used.

Problem: Waves on only one side of the output

Hints: • Check the nip setting of main rolls

• Check for even paper tension

Problem: Angled waves in the output on both sides

Hints: • Check for insufficient main roller pressure

• Check the main roller nip settings

Problem: Indent waves in output after the pull rollers

Hints: • Output travel was hindered

• Allow output to cool before handling

• Check operating temperatures of material

Page 7 - 3

TroubleshootingF 60 H Operation and Maintenance Manual

7.2 Film problems

The following is a list of common film problems

you may encounter.

For definitions of terminologies, please refer to

7.4 Glossary of terminology.

Pressure sensitive

Problem : Silvering in the laminate

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

temperature

• Increase pressure to laminating rolls

Problem : Tunneling

Hints : • Print should be wound image side out.

• Do not roll tightly

• Do not roll at all.

Problem: Delamination

Hints: • Check operating pressures

• Check operating speed

• Laminate compatibility with ink

• Ink compatibility with paper

Lo-Melt laminates

Problem: Blistering within the image

Hints: • Increase the speed

• Decrease the operating temperature

• Allow a longer drying time for the image

Problem: Silvering in the laminate

Hints: • Decrease the speed

• Increase the operating temperature

Problem: Delamination

Hints: • Check operating temperatures

• Check operating speed

• Laminate compatibility with ink

• Ink compatibility with paper

Mounting

Problem : Image creases when mounting

Hints : • Press down on leading edge from center

outwards.

• Be sure image is conformed to the roll

• Use a speed you are comfortable with

• Be sure even tension is supplied to the image

Page 7 - 4

Troubleshooting F 60 H Operation and Maintenance Manual

7.3 Machine problems

Once the Hints are all checked, and your problem

still exists, a service call must be placed for a qualified

service personnel to fix the problem.

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.

My Falcon 60 H Laminator serial # is :

At no time does GBC Films Group suggest or

recommend that you attempt to fix the machine by

removing the cabinets or leg covers yourself.

WARNING

Do not wear ties, loose fitting clothing or

dangling jewelry while operating or

servicing the laminator. These items can get

caught in the nip and choke you or you can

be crushed or burned.

Problem : No illumination to the control panel

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

down

• Press RESET.

• Confirm that the MAIN POWER is to the

on position.

• Be sure power is supplied to the laminator

Problem : I can only operate using the footswitch.

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

• Place a service call to calibrate sensors.

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

Hints : • Be sure a speed has been set.

• Make sure a motor direction has been

selected.

• Ensure the PHOTO-EYE is not blocked.

Problem : Jerking, stuttering, or excessive noise from

the laminator.

Hints : • Check for excessive brake tension

• Confirm that the rolls of laminate are on

correctly.

• Check for proper chain tension.

• Place a service call.

Page 7 - 5

TroubleshootingF 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.

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.

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.

Center mount

A mounting technique where an image is mounted

centrally on a substrate to provide a decorative border.

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.

Cold laminate

Film that does not require heat to activate the

adhesive. Please see P.S.A. for more information.

Craft paper

A strong brown paper commonly used for single

sided applications.

D waves

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.

Edgewrap

A mounting technique where the image wraps

around the edges of the mounting substrate so as to provide

a finished edge.

Encapsulation

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.

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.

Page 7 - 6

Troubleshooting F 60 H Operation and Maintenance Manual

Foamboard

A material commonly used as a mounting

substrate. It is made up of foam sandwiched between

two layers of paper, or paper like media.

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.

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.

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.

Media

Term used to describe the materials used to print

an image, i.e. the papers, inks, toners, etc.

Mount adhesive

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.

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.

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.

Rewind

A system that rolls up media. The rewind tube (s)

used on the Falcon 60 H laminator is a prime example.

Roll to roll

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.

Page 7 - 7

TroubleshootingF 60 H Operation and Maintenance Manual

Scarring

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.

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.

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.

Unwind

A system that unwinds media. Unwinds are used

on all laminators to dispense laminate for lamination.

Web

The path that rolled media unwinding from a supply

roll takes through a machine or array of rollers.

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Troubleshooting F 60 H Operation and Maintenance Manual

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Page 8 - 1

MaintenanceF 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.

WARNING

Do not wear ties, loose fit clothing or

dangling jewelry while operating or

servicing the laminator. These items can get

caught in the nip and choke you or you can

be crushed or burned.

INFORMATION

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.

8.1 Maintenance Schedule

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.

INFORMATION

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 )

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 - 2

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.

POWER

Off

b) Press machine RESET.

POWER

Reset

Page 8 - 3

MaintenanceF 60 H Operation and Maintenance Manual

c) Set motor direction to REV.

(reverse) (forward)

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

Excessive pressure can destroy the silicone

layer by pressing to hard or scrubbing

too long in one spot.

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.

f) Wipe away the beads with isopropyl alcohol

and a cotton terry cloth.

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!

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.

WARNING

When operating the laminator using the

footswitch, keep hands and fingers

away from the nip of the rollers.

You may be CRUSHED or BURNED!

d) Use the footswitch to rotate the rollers when

finished cleaning that area.

Page 8 - 4

Maintenance F 60 H Operation and Maintenance Manual

8.3 Clean cabinets and covers

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.

b) If water is not strong enough, you may use a

mild dishwashing detergent with water and a

cotton terry cloth.

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.

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 only a slightly damp ( water only ) non

abrasive cloth.

b) The same type of cloth used to clean eye

glasses may be used instead.

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.

Page 8 - 5

MaintenanceF 60 H Operation and Maintenance Manual

8.5 Chain tensioning

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.

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.

Remove ALL power to the laminator before

removing any cabinet covers.

You may be shocked or electrocuted!

WARNING

Always practice lock out/ tag out procedures

when performing any type of service or

maintenance work on the machine.

Tools required

• 1/8 inch allen wrench

• 7/16 inch wrench or socket

a) Ensure all power to the laminator has been

removed.

b) Use proper lock out/ tag out procedure.

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.

PRO-TECH

F 60 H

Page 8 - 6

Maintenance F 60 H Operation and Maintenance Manual

d) Check the primary chain ( outer ) and the

secondary chain ( inner ) for proper chain

tension.

Primary chain

Secondary chain

e) If the chains require tensioning, loosen the four

motor mount bolts with a 7/16 in. wrench.

Four bolts

INFORMATION

The motor controls the tension of the both

chains. If one is chain is still too loose,

a half link may be removed.

f) Press firmly down on the motor housing and

tighten the motor mount bolts.

Press

firmly

here

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.

MyBinding Gbc F60H Manual User

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