GBC Laminator 930 400 User Manual
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© 1997 GBC Pro-Tech  
Do not duplicate without written permission  
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GBC Pro-Tech  
4151 Anderson Road  
De Forest, Wisconsin 53532  
Tel: 608-246-8844  
Part Number 930-400  
Fax: 608-246-8645  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Falcon 36 Operation Manual  
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Caution/Warning Label Locations........................................................................................1-4  
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Preinstallation Checklist.......................................................................................................2-1  
Unpacking............................................................................................................................2-4  
Setup ...................................................................................................................................2-7  
Startup .................................................................................................................................2-8  
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Safety...................................................................................................................................3-1  
Operator Controls ................................................................................................................3-2  
Front Control Panel ..........................................................................................................3-2  
Rear Panel Control...........................................................................................................3-2  
Setup ...................................................................................................................................3-3  
Laminator Roll Pressure...................................................................................................3-3  
Loading the Film ..................................................................................................................3-3  
Positioning the Film..............................................................................................................3-3  
Heating.................................................................................................................................3-4  
Cooling.................................................................................................................................3-4  
Paper Tips ...........................................................................................................................3-4  
Process Control Charts........................................................................................................3-5  
Mounting and Laminating (One Pass) .................................................................................3-5  
Setup and Procedure........................................................................................................3-5  
Mounting Only......................................................................................................................3-6  
Setup and Procedure........................................................................................................3-6  
Two-Pass Mount and Laminate (Cold Overlaminate) ..........................................................3-6  
Setup and Procedure, Pass 1...........................................................................................3-6  
Setup and Procedure, Pass 2...........................................................................................3-7  
Two-Pass Mount and Laminate (Hot Overlaminate)............................................................3-7  
Setup and Procedure, Pass 1...........................................................................................3-7  
Setup and Procedure, Pass 2...........................................................................................3-7  
Encapsulation ......................................................................................................................3-8  
Setup and Procedure........................................................................................................3-8  
Machine Shutdown ..............................................................................................................3-8  
GBC Pro-Tech 1997 October  
iii  
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Falcon 36 Operation Manual  
Procedure.........................................................................................................................3-8  
PROCESS CONTROL CHART............................................................................................3-9  
PROCESS CONTROL DIAGRAM .......................................................................................3-9  
PROCESS CONTROL CHART 3-2 ...................................................................................3-10  
PROCESS CONTROL DIAGRAM 3-2...............................................................................3-10  
PROCESS CONTROL CHART 3-3 ...................................................................................3-11  
PROCESS CONTROL DIAGRAM 3-3...............................................................................3-11  
PROCESS CONTROL CHART 3-4a .................................................................................3-12  
PROCESS CONTROL DIAGRAM 3-4a.............................................................................3-12  
PROCESS CONTROL CHART 3-4b .................................................................................3-13  
PROCESS CONTROL DIAGRAM 3-4b.............................................................................3-13  
PROCESS CONTROL CHART 3-5a .................................................................................3-14  
PROCESS CONTROL DIAGRAM 3-5a.............................................................................3-14  
PROCESS CONTROL CHART 3-5b .................................................................................3-15  
PROCESS CONTROL DIAGRAM 3-5b.............................................................................3-15  
PROCESS CONTROL CHART 3-6 ...................................................................................3-16  
PROCESS CONTROL DIAGRAM 3-6...............................................................................3-16  
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Thermocouple Positioning and Cleaning .............................................................................4-1  
Cleaning...............................................................................................................................4-4  
Adjusting the Nip..................................................................................................................4-5  
Chain Tensioning.................................................................................................................4-6  
Lubrication ...........................................................................................................................4-7  
Contacting Technical Support..............................................................................................4-7  
Output Troubleshooting Guide.............................................................................................4-9  
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Limited Warranty..................................................................................................................5-1  
Exclusions to the Warranty...............................................................................................5-1  
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Specifications.......................................................................................................................6-1  
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iv  
GBC Pro-Tech 1997 October  
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Falcon 36 Laminator Service Manual  
Safety and Warranty Information  
GBC Pro-Tech laminators are powerful machines  
that are designed to mount, laminate and  
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encapsulate. The forces required to accomplish  
these tasks can vary from negligible to very large.  
DO NOT ATTEMPT TO OPERATE YOUR  
FALCON 36 LAMINATOR UNTIL YOU  
HAVE READ THIS SECTION  
CAREFULLY!  
The spring system used to provide downward  
pressure on the top roll is capable of producing  
forces greater than 1000 pounds (454kg). This force  
is applied to any object presented in the opening  
(called the nip) between the two rolls.  
Your safety, as well as the safety of others, is  
important to GBC Pro-Tech. This section contains  
important safety information.  
In addition, the laminating rolls of the Falcon 36 can  
reach temperatures of over 200°F (100°C). At these  
temperatures there is a danger of a severe burn if the  
rolls are touched during set-up, operation or  
servicing.  
The following symbols are used throughout this  
manual to indicate warnings and cautions.  
DANGER  
An important feature of the laminator is the  
photoelectric eye system that stops the machine  
when objects move into the nip area. Once the  
blocking object is removed and the light beam  
reestablished, the rolls resume turning. However,  
this system is overridden if you use the footswitch.  
Indicates an imminently hazardous situation  
which, if not avoided, will result in death or  
serious injury.  
WARNING  
WARNING  
Indicates a potentially hazardous situation  
which, if not avoided, could result in death or  
serious injury.  
Use extreme caution when operating the  
laminator with the footswitch. The  
photoelectric eye system is overridden and  
your fingers can get caught in the nip. You  
can be crushed or burned.  
CAUTION  
Indicates a potentially hazardous situation  
which, if not avoided, could result in minor  
or moderate injury, or alerts against unsafe  
practices, or alerts against actions which  
could damage the product.  
The Falcon 36 Laminator has a steel cabinet that is  
bolted closed to isolate the electrical and drive  
system components for the safety of the operator.  
Only a qualified service technician should open  
these cabinets.  
The laminator is equipped with two emergency stop  
buttons located on the top of either side of the  
laminator. Either of these, if engaged, stops the  
laminator. To continue operation both emergency  
stop buttons must be in the up position.  
The Falcon 36 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.  
GBC Pro-Tech 1997 October  
1-1  
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Safety and Warranty Information  
Falcon 36 Laminator Service Manual  
Push either  
button to stop the  
laminator  
Twist and pull up  
both buttons to  
CAUTION  
resume operation  
ALWAYS CHECK THE POSITION AND  
CONDITION OF THE THERMOCOUPLES  
PRIOR TO OPERATION! The thermal  
junction of the thermocouples MUST make  
contact with the laminating rolls to maintain  
proper roll operating temperatures. The  
thermocouples must also be free of adhesive  
and dirt. The rolls can overheat and cause a  
fire or seriously damage the laminator.  
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Figure 1-1: Using the Emergency Stop Buttons  
Despite the safety features built into the Falcon 36  
Laminator, extreme caution must be used when  
operating or servicing the unit. READ THE  
FOLLOWING WARNINGS AND CAUTIONS  
BEFORE ATTEMPTING TO OPERATE OR  
SERVICE THE FALCON 36 LAMINATOR.  
WARNING  
Always use care in lowering the top  
laminating roll. You can be crushed or  
burned.  
WARNING  
Never place fingers or arms between the rolls  
when they are turning or when the rolls are  
in the closed position. You can be crushed or  
burned.  
WARNING  
Do not operate the laminator near water.  
You can be severely shocked, electrocuted or  
cause a fire.  
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.  
DANGER  
Unplug the laminator from the wall outlet  
before servicing. You can be severely  
shocked, electrocuted or cause a fire.  
WARNING  
WARNING  
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.  
Use extreme caution when operating the  
laminator with the footswitch. The  
photoelectric eye system is overridden and  
your fingers can get caught in the nip. You  
can be crushed or burned.  
GBC Pro-Tech 1997 October  
1-2  
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Falcon 36 Laminator Service Manual  
Safety and Warranty Information  
WARNING  
WARNING  
Exercise care when cleaning the rolls with  
80% isopropyl alcohol:  
The operating environment must be free of  
dust, flammable liquids and vapors. You can  
be injured by inhaling chemical vapors.  
Vapor build up or stored flammable liquids  
can cause a fire. Excessive dust can damage  
the laminator.  
• Use only in a well ventilated area.  
• Wear rubber gloves.  
• Use only on cool rolls.  
Cleaning heated rolls can ignite the fumes.  
CAUTION  
Do not use a knife or other sharp instrument  
during installation or while servicing the  
laminator. You can cause irreparable  
damage to the rolls.  
CAUTION  
Use only 80% isopropyl alcohol or a rubber  
cement eraser to clean the laminating rolls.  
Harsh chemicals like toluene, acetone or  
MEK destroy the silicone covering of the  
rolls.  
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.  
CAUTION  
Raise the upper main roll when the  
laminator is not in operation. Prolonged  
contact can damage the rolls.  
The Falcon 36 Laminator is a large and  
heavy piece of equipment. It is necessary to  
employ LICENSED RIGGERS ONLY to  
move the machine. The laminator is not  
designed to be tipped up or sideways in any  
way. Such action disturbs the exact  
alignment of the rolling parts of the machine  
and requires extensive realignment. GBC  
Pro-Tech’s warranty does not cover  
malfunction of the equipment due to  
mishandling and/or tipping.  
CAUTION  
Excess pressure can damage the laminating  
rolls. Always select the minimum roll  
pressure necessary to complete the task.  
GBC Pro-Tech bears no responsibility for  
personal injury or damage due to moving the  
laminator improperly.  
CAUTION  
If silicone adhesive contacts the upper or  
lower roll, remove it IMMEDIATELY using  
80 % isopropyl alcohol. It can harden within  
an hour and ruin the roll.  
GBC Pro-Tech 1997 October  
1-3  
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Safety and Warranty Information  
Falcon 36 Laminator Service Manual  
WARNING  
WARNING  
Connect the laminator only to the type of  
power source indicated on the label on the  
back of the laminator. You can be severely  
shocked, electrocuted or cause a fire. If you  
are not sure of the type of power available  
consult the dealer or local power company.  
Do not attempt to plug any device into the  
vacuum table outlet that does not require  
240V. You can be severely shocked,  
electrocuted or cause a fire.  
WARNING  
Never insert objects of any kind through any  
of the slots on the laminator. You can touch  
dangerous voltage points or short out parts.  
You can be severely shocked, electrocuted or  
cause a fire.  
WARNING  
Do not attempt to defeat the grounding  
feature of the ground plug on the laminator.  
You can be severely shocked, electrocuted or  
cause a fire. The three prong plug fits only  
into a grounding-type power outlet. If you  
are unable to insert the plug into the existing  
outlet, contact a qualified electrician to  
replace the obsolete outlet.  
ALWAYS USE GOOD SAFETY PRACTICES  
WHEN OPERATING OR SERVICING THE  
LAMINATOR AND KNOW HOW TO REACT  
QUICKLY IN AN EMERGENCY.  
WARNING  
&DXWLRQꢋ:DUQLQJꢀ/DEHOꢀ/RFDWLRQV  
Posted at various locations on your Falcon 36  
Laminator are important safety labels. PAY  
CAREFUL ATTENTION TO THESE LABELS AT  
ALL TIMES! Figure 1-2 shows the location of each  
of these labels.  
Do not use an extension cord on this  
laminator. You can be severely shocked,  
electrocuted or cause a fire. If you need a  
longer cable contact a qualified electrician.  
WARNING  
Do not operate the laminator if the power  
cord is damaged or frayed. You can be  
severely shocked, electrocuted or cause a fire.  
Contact a qualified electrician to replace the  
cord.  
WARNING  
Do not allow anything to rest on the power  
cord. Do not locate the cord where people  
can walk on it. You or others can be severely  
shocked, electrocuted or cause a fire.  
GBC Pro-Tech 1997 October  
1-4  
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Falcon 36 Operation Manual  
Safety  
WARNING  
ACHTUNG  
MISE EN GARDE  
WARNING  
SAFETY  
INSTRUCTIONS  
ACHTUNG  
SICHERHEITS-  
RICHTLINIEN  
MISE EN GARDE  
CONSIGNES DE  
SÉCURITÉ  
1. Read and understand the Operation  
Manual and all safety labels before  
operating this machine.  
WARNING  
ACHTUNG  
MISE EN GARDE  
2. Only a trained person is to be  
permitted to operate this machine.  
Training should include instruction  
in operation under normal conditions  
and emergency situations.  
Crush and burn  
hazard. Stay clear  
of moving rollers.  
Stop machine and  
raise roll before  
cleaning.  
Moving parts can  
crush and cut.  
Do not operate with  
door open.  
3. This machine is to be serviced only  
by trained and authorized personnel.  
Follow lockout procedures before  
servicing.  
©1994 HCS, Inc. 800-748-0241  
Reorder No. 1012-PT  
©1994 HCS, Inc. 800-748-0241  
Reorder No.1033R-PT  
4. Never reach into the machine for any  
reason unless the machine is at a  
COMPLETE STOP.  
D
Y
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U
C
R
N
E
G
E
G
N
R E  
C
E
M
E
S
U A  
T
N O  
5. Never leave the machine stopped in  
such a manner that another worker can  
start the machine while you are working  
on or within the machine.  
ARNING  
W
CHTUNG  
A
Crush and burn  
hazard. Stay clear  
of moving rollers.  
Stop machine and  
raise roll before  
cleaning.  
MISE EN GARDE  
6. Never change or defeat the function of  
electrical interlocks or other machine  
“shutdown” switches.  
urn  
lear  
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s.  
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SAFETY  
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RICHTLINIEN  
7. Before starting this machine, check that:  
- All persons are clear of the machine.  
- No maintenance work is being performed  
on the machine.  
- All guards are in place.  
- All parent rolls are well chucked in the  
unwind stands.  
CONSIGNES DE  
SÉCURITÉ  
1
.
Read and under  
Man  
ual and all saf  
operating this mac  
stand the Operation  
©1994 HCS, Inc. 800-748-0241  
Reorder No.1033-PT  
2
.
Onl  
ety labels bef  
y
a
trained per  
permitted to operate this mac  
hine  
.
T
raining should inc  
ore  
in operation under normal conditions  
son is to be  
and emer  
lude instruction  
g
his mac  
enc  
y
hine  
.
situations.  
hine is to be ser  
ined and authoriz  
F
ser  
ARNING  
W
vicing.  
or  
ocedur  
reason unless the mac  
COMPLETE ShTinto the mac  
4
viced onl  
ds pberf  
sonneyl.  
.
Ne  
ver reac  
e
e
CHTUNG  
A
-The machine is free of paper scraps,  
wraps and jams.  
ore  
5
.
Ne  
ver lea  
suc  
hine  
f
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MISE EN GARDE  
.
hine is at  
a
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w
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y
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the mac  
on or within the mac  
hine stopped in  
hine while  
6
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.
orking  
7
s
.
eat the function of  
ks or other mac  
8. There is a potential hazard of entanglement  
in this machine caused by items such as  
long hair, loose clothing and jewelry.  
Make sure your clothing and hair fit  
closely to your body and that all jewelry,  
rings and watches are removed.  
witc  
hes.  
etwhis mac  
-
All per  
-
No maintenatin  
ng  
c
sons are  
c
urn  
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on the mac  
All guar  
hine  
y
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s.  
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All parent  
r
Staoller  
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hine  
unwind stands.  
,
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ds are in placo  
e
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ving  
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.
k
that:  
-
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hazar  
of mo  
The mac  
olls are well  
ore  
oll bef  
Reorder No.1033-PT  
wraps and jams.  
.
.
hine is free of paper scraps,  
ormed  
8
Stop mac  
.
huc  
There is  
a
potential hazar  
ked in the  
in this mac  
raise  
r
leaning.  
long hair  
c
Make sure  
y
hine caused  
b
,
loose  
c
c
©1994 HCS, Inc. 800-748-0241  
losel  
d
of entanglement  
rings anydto  
w
y
atcour  
lothing and je  
c
©1994 HS
y
items suc  
our bodlothing and hair fit  
y
and that all eelr  
j
w
hes are remo  
h
as  
y
.
ved.  
welr  
y
,
Reorder
©1994 HCS, Inc. 800-748-0241  
Reorder No.7002-PT  
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240 VOLTS  
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8
LEM PRODUCTIONS, INC. DOYLESTOWN PA  
LVM-240C  
F
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©1994
.
Obser  
ve  
ety  
Rr
240 VOLTS  
LEM PRODUCTIONS, INC. DOYLESTOWN PA  
LVM-240C  
WARNING  
ACHTUNG  
MISE EN GARDE  
DANGER  
GEFAHR  
HAZARDOUS  
Carefully read Operator's  
Manual before handling  
this machine. Observe  
instructions and safety  
rules when operating.  
VOLTAGE.  
To be serviced only  
by trained and  
authorized personnel.  
Lockout power before  
servicing.  
©1994 HCS, Inc. 800-748-0241  
Reorder No.6001-PT  
©1994 Hazard Communication Systems, Inc. 800-748-0241  
Reorder No. 5025-PT  
Figure 1-2: Locations of Safety Labels  
1-5  
GBC Pro-Tech 1997 October  
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Safety  
Falcon 36 Operation Manual  
Blank page.  
GBC Pro-Tech 1997 October  
1-6  
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Falcon 36 Operation Manual  
Installation  
6HFWLRQꢀꢇꢀꢄꢀ,QVWDOODWLRQ  
CAUTION  
Before a Falcon 36 Laminator can be installed there  
are a few requirements that must be met. Make  
certain that each of the requirements listed in the  
following preinstallation checklist are met before  
beginning installation.  
Do not locate the laminator where air is  
blowing directly on the machine. The air flow  
can cool the rolls unevenly and result in poor  
quality output.  
❒ Is there an appropriate power outlet available or  
has a certified electrician been contacted to wire  
the laminator directly?  
CAUTION  
The laminator requires 30A single phase service  
and a power receptacle that accepts a 30A 250V  
NEMA L6-30P plug.  
Failure to follow the preinstallation checklist  
can result in damage to the laminator.  
3UHLQVWDOODWLRQꢀ&KHFNOLVW  
WARNING  
❒ Are doorways and hallways wide enough for the  
laminator to be moved to the installation site?  
Do not attempt to defeat the grounding  
feature of the ground plug on the laminator.  
You can be severely shocked, electrocuted or  
cause a fire. The three prong plug fits only  
into a grounding-type power outlet. If you  
are unable to insert the plug into the existing  
outlet, contact a qualified electrician to  
replace the obsolete outlet.  
❒ Is there ample room for the laminator?  
A work area must be established that allows for  
operation in both the front and the rear of the  
machine and provides space for efficient  
material flow. Figure 2-1 shows a typical  
machine area layout.  
❒ Is the environment appropriate for the  
laminator?  
The laminator requires a clean, dust and vapor  
free environment to operate properly. It must not  
be located where there is air blowing directly on  
the machine.  
WARNING  
Do not use an extension cord on this  
laminator. You can be severely shocked,  
electrocuted or cause a fire. If you need a  
longer cable contact a qualified electrician.  
WARNING  
The operating environment must be free of  
dust, flammable liquids and vapors. You can  
be injured by inhaling chemical vapors.  
Vapor build up or stored flammable liquids  
can cause a fire. Excessive dust can damage  
the laminator.  
WARNING  
Do not operate the laminator if the power  
cord is damaged or frayed. You can be  
severely shocked, electrocuted or cause a fire.  
Contact a qualified electrician to replace the  
cord.  
2-1  
GBC Pro-Tech 1997 October  
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Installation  
Falcon 36 Operation Manual  
WARNING  
Do not allow anything to rest on the power  
cord. Do not locate the cord where people  
can walk on it. You or others can be severely  
shocked, electrocuted or cause a fire.  
GBC Pro-Tech 1997 October  
2-2  
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Falcon 36 Operation Manual  
Installation  
Recommended  
clearance  
10'  
(~3m)  
4'6" (~1.1m)  
2'2"  
(~.7m)  
3' (~1m)  
10'  
(~3m)  
Figure 2-1: Laminator Space Requirements  
GBC Pro-Tech 1997 October  
2-3  
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Installation  
Falcon 36 Operation Manual  
8QSDFNLQJ  
NOTE  
ALL SHIPMENTS ARE EX- WORKS. At our dock  
title passes to the buyer Please review your  
insurance coverage prior to shipment, as you are  
responsible for all subsequent freight charges and  
risks. Before signing the Bill of Lading they should  
be sure to inspect the crate and/or pallet for signs of  
damage or missing items; if applicable, they should  
make a note of this on the Bill of Lading.  
The Falcon 36 Laminator is shipped one of two  
ways. It is either encased in a plywood crate on a  
skid or in a cardboard box on a skid.  
Figure 2-2: Removing the Cardboard Box  
WARNING  
2. Lift the cardboard box off the laminator.  
The unpacking process requires at least two  
people. You can be severely injured or  
crushed.  
3. Gently unwrap the shrink wrap from around the  
laminator.  
Tools required:  
CAUTION  
•
•
Phillips head screwdriver  
7/8" open end wrench or adjustable wrench  
Do not use a knife or other sharp instrument  
during installation or while servicing the  
laminator. You can cause irreparable  
damage to the rolls.  
If the laminator is in a cardboard box:  
1. Remove the securing screws around the bottom  
of the box using the Phillips head screwdriver as  
shown in Figure 2-2.  
4. Carefully remove any accessories packed with  
the laminator. The accessory pack should  
contain:  
1 Set, hex wrenches  
1 Slitting knife  
1 Manual  
1 Set, spare fuses  
1 Tape measure  
1 Roll of masking tape  
1 Rubber cement eraser  
GBC Pro-Tech 1997 October  
2-4  
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Falcon 36 Operation Manual  
Installation  
CAUTION  
Do not use a knife or other sharp instrument  
during installation or while servicing the  
laminator. You can cause irreparable  
damage to the rolls.  
Foot Bolt  
9. Remove all packing materials to a safe distance  
from the laminator.  
Shipping  
Pad  
A NOTE ABOUT RECYCLING  
Figure 2-3: Removing the Packing Assemblies  
The pallet can be reused for shipping the machine  
again, or can be disassembled and the wood and  
screws recycled. The cardboard can be recycled.  
The shrink wrap is not recyclable, however, so it  
must be discarded.  
5. Remove the screws holding the foot pads onto  
the pallet using the Phillips head screwdriver.  
6. Have the laminator lifted off the skid and placed  
on the floor by licensed riggers. The riggers  
must also unscrew the foot bolts from the  
laminator frame since it requires lifting the  
laminator.  
NOTE  
A word about international shipments: As these are  
heavy pieces of equipment, GBC Pro-Tech takes  
every precaution to ensure that our laminators are  
properly crated to the highest standards.  
WARNING  
Before machines leave our loading dock, they are  
pre-treated with a VCI protective film to provide  
total corrosion protection. This protective film is  
wrapped around the machine and completely sealed.  
In addition, moisture absorbing silicone desiccite  
packs are packed inside the crate and machine  
cabinets.  
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.  
The Falcon 36 Laminator is a large and  
heavy piece of equipment. It is necessary to  
employ LICENSED RIGGERS ONLY to  
move the machine. The laminator is not  
designed to be tipped up or sideways in any  
way. Such action disturbs the exact  
alignment of the rolling parts of the machine  
and requires extensive realignment. GBC  
Pro-Tech’s warranty does not cover  
malfunction of the equipment due to  
mishandling and/or tipping.  
Prior to start up of the machine, you must remove  
the desiccite packs from each cabinet and discard.  
DO NOT operate the machine with the desiccite  
packs inside the cabinets.  
GBC Pro-Tech bears no responsibility for  
personal injury or damage due to moving the  
laminator improperly.  
7. Once the laminator is in place set the locking  
mechanism on all four wheels to ON.  
8. Remove any plastic strapping and packing paper  
taped to the rolls.  
2-5  
GBC Pro-Tech 1997 October  
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Installation  
Falcon 36 Operation Manual  
If the laminator is in a crate:  
CAUTION  
1. Remove the top of the crate and then the sides in  
the order shown in Figure 2-4.  
Do not use a knife or other sharp instrument  
during installation or while servicing the  
laminator. You can cause irreparable  
damage to the rolls.  
CAUTION  
3. Carefully remove any accessories packed with  
the laminator. The accessory pack should  
contain:  
Do not allow the top to fall into the crate. It  
can damage the laminator.  
1 Set, hex wrenches  
1 Slitting knife  
1 Manual  
1 Set, spare fuses  
1 Tape measure  
Do not put packing screws on the floor. They  
can cause problems when trying to roll the  
machine into position.  
1 Roll of masking tape  
1 Rubber cement eraser  
A second person must support the side  
labeled 5 in Figure 2-4. It can fall and  
damage the laminator.  
Foot Bolt  
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the pallet using the Phillips head screwdriver.  
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5. Have the laminator lifted off the skid and placed  
on the floor by licensed riggers. The riggers  
must also unscrew the foot bolts from the  
laminator frame since it requires lifting the  
laminator.  
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Figure 2-4: Removing the Crate  
2. Gently unwrap the shrink wrap from around the  
laminator.  
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Falcon 36 Operation Manual  
Installation  
NOTE  
A word about international shipments: As these are  
heavy pieces of equipment, GBC Pro-Tech takes  
every precaution to ensure that our laminators are  
properly crated to the highest standards.  
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.  
Before machines leave our loading dock, they are  
pre-treated with a VCI protective film to provide  
total corrosion protection. This protective film is  
wrapped around the machine and completely sealed.  
In addition, moisture absorbing silicone desiccite  
packs are packed inside the crate and machine  
cabinets.  
The Falcon 36 Laminator is a large and  
heavy piece of equipment. It is necessary to  
employ LICENSED RIGGERS ONLY to  
move the machine. The laminator is not  
designed to be tipped up or sideways in any  
way. Such action disturbs the exact  
alignment of the rolling parts of the machine  
and requires extensive realignment. GBC  
Pro-Tech’s warranty does not cover  
malfunction of the equipment due to  
mishandling and/or tipping.  
Prior to start up of the machine, you must remove  
the desiccite packs from each cabinet and discard.  
DO NOT operate the machine with the desiccite  
packs inside the cabinets.  
6HWXS  
GBC Pro-Tech bears no responsibility for  
personal injury or damage due to moving the  
laminator improperly.  
Once the Falcon 36 Laminator has been unpacked  
and moved into final position check each of the  
following items.  
6. Once the laminator is in place set the locking  
mechanism on all four wheels to ON.  
Tools required:  
7. Remove any plastic strapping and packing paper  
taped to the rolls.  
•
•
1/8" hex wrench  
Adjustable wrench  
Setup Procedure  
CAUTION  
1. Inspect the laminator for any obvious shipping  
damage.  
Do not use a knife or other sharp instrument  
during installation or while servicing the  
laminator. You can cause irreparable  
damage to the rolls.  
2. Remove the drive and control side cabinet  
covers with the 1/8" hex wrench by removing the  
six screws holding each cover in place.  
8. Remove all packing materials to a safe distance  
from the laminator.  
3. Inspect all the bolts and tighten any that were  
loosened during shipping.  
A NOTE ABOUT RECYCLING  
4. Check the upper main roll assembly by using the  
handwheel to raise and lower the roll. It should  
move smoothly.  
The crate components can be reused for shipping  
the machine again, or can be disassembled and the  
wood and screws recycled. The shrink wrap is not  
recyclable, however, so it must be discarded.  
5. Set the nip. (See Section 4: Maintenance and  
Troubleshooting for the procedure.)  
6. Verify that both thermocouples make contact  
with the rolls. (See Section 4: Maintenance and  
Troubleshooting for the procedure.)  
2-7  
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Installation  
Falcon 36 Operation Manual  
❒ Is the photoelectric eye system working?  
With the laminator running, place an object  
approximately the size of your hand just in front  
of the nip to confirm that the photoelectric eye  
system is functioning. The rolls should stop.  
Move the object away from the nip. The  
laminator should resume operation.  
WARNING  
ALWAYS CHECK THE POSITION AND  
CONDITION OF THE THERMOCOUPLES  
PRIOR TO OPERATION! The thermal  
junction of the thermocouples MUST make  
contact with the laminating rolls to maintain  
proper roll operating temperatures. The  
thermocouples must also be free of adhesive  
and dirt. The rolls can overheat and cause a  
fire or seriously damage the laminator.  
WARNING  
Never operate the laminator unless the  
photoelectric eye system is functioning  
properly. You can be crushed or burned.  
7. Plug the laminator into an approved socket or  
have a certified electrician wire the laminator  
directly to a power source.  
❒ Is the motor functioning?  
8. Verify that the photoelectric eye is working  
properly. (See the procedure below.)  
Test the motor at various speeds ranging from  
0-18. At 0 the rolls should stop turning.  
Run the motor in both forward and reverse.  
9. Replace both cabinet covers.  
❒ Are the heaters working?  
Verify that the top heater controller heats the  
top roll and the bottom heater controller heats  
the bottom roll.  
6WDUWXS  
The first time the laminator is started and every time  
it is serviced you should use the following checklist  
to confirm that the unit is operating properly and  
that all safety mechanisms are functioning.  
❒ Is the footswitch operating?  
Test the footswitch for both forward and reverse  
operation. Verify that the footswitch overrides  
the photoelectric eye by pressing the footswitch  
and pushing an object as large as your hand into  
the nip area.  
Startup Checklist  
Start the laminator and go through the following  
checklist.  
Once you have completed the startup checklist you  
can safely run a test sample.  
❒ Are the emergency stop buttons working?  
Push down on one of the emergency stop  
buttons. The laminator should stop. Pull up on  
the button. The laminator should resume  
operation. Always check both buttons.  
WARNING  
Never operate the laminator unless both of  
the emergency stop buttons are functioning  
properly. You can be crushed or burned.  
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Falcon 36 Operation Manual  
Operation  
Push either  
button to stop the  
laminator  
Twist and pull up  
both buttons to  
resume operation  
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GBC Pro-Tech laminators are powerful machines  
that are designed to mount, laminate and  
encapsulate. The forces required to accomplish  
these tasks can vary from negligible to very large.  
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The spring system used to provide downward  
pressure on the top roll is capable of producing  
forces greater than 1000 pounds (454kg). This force  
is applied to any object presented in the opening  
(called the nip) between the two rolls.  
Figure 3-1: Using the Emergency Stop Buttons  
Despite the safety features built into the Falcon 36  
Laminator, extreme caution must be used when  
operating or servicing the unit.  
In addition, the laminating rolls of the Falcon 36 can  
reach temperatures of over 200°F (100°C). At these  
temperatures there is a danger of a severe burn if the  
rolls are touched during set-up, operation or  
servicing.  
An important feature of the laminator is the  
photoelectric eye system that stops the machine  
when objects move into the nip area. Once the  
blocking object is removed and the light beam  
reestablished, the rolls resume turning. However,  
this system is overridden if you use the footswitch.  
WARNING  
Use extreme caution when operating the  
laminator with the footswitch. The  
photoelectric eye system is overridden and  
your fingers can get caught in the nip. You  
can be crushed or burned.  
The Falcon 36 Laminator has a steel cabinet that is  
bolted closed to isolate the electrical and drive  
system components for the safety of the operator.  
Only a qualified service technician should open  
these cabinets.  
The laminator is equipped with two emergency stop  
buttons located on the top of either side of the  
laminator. Either of these, if engaged, stops the  
laminator. To continue operation both emergency  
stop buttons must be in the up position.  
3-1  
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Operation  
Falcon 36 Operation Manual  
7. POWER LIGHT – Indicates when the main  
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power is being applied to the machine.  
The operator controls for the Falcon 36 Laminator  
are located on the front and rear of the unit, to the  
right of the operator position. The names and  
functions of these controls are as follows:  
8. UPPER ROLL HEATER CONTROLLER –  
Provides a readout of the temperature of the  
upper roll and the set-point for the desired  
temperature. (See Figure 3-3.)  
9. LOWER ROLL HEATER CONTROLLER–  
Provides a readout of the temperature of the  
lower roll and the set-point for the desired  
temperature. (See Figure 3-3.)  
Speed Adjustment  
MOTOR  
FWD  
AUTO  
6
9
12  
6
175  
1
2
OUT  
125  
HI  
Motion Control  
FORWARD/  
REVERSE  
Foot Switch/  
Continuous Run  
AUTO/STOP  
3
15  
150  
200  
Red: Set point has  
not been reached  
Solid: Temperature is  
within 5° of set point  
0
18  
225  
REV  
SPEED  
STOP  
Green: Temperature  
is exactly at set point  
Blinking: Temperature  
is greater than 5° of set  
point  
FANS  
100  
75  
250  
275  
1
POWER  
7
Off: Set point has been  
reached or exceeded  
3
4
5
Cooling Fans  
Power Light  
ON/Off  
O
.
50  
PROTECH  
300  
001-133  
Solid: Temperature is  
within 5° of set point  
HEATERS  
LO  
°F  
175  
OUT  
HI  
150  
200  
1
125  
225  
Blinking: Temperature is  
lower than 5° of set point  
T
O
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100  
75  
250  
275  
8
Top Roll Heater  
Controller  
Upper Roll Heat  
ON/OFF  
50  
300  
001-133  
Off: Set point has been  
reached or exceeded  
O
LO  
PROTECH  
°F  
175  
OUT  
150  
HI  
B
O
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200  
1
125  
225  
Figure 3-3: Heater Controller  
100  
75  
250  
275  
9
Lower Roll Heat  
ON/OFF  
Lower Roll Heater  
Controller  
T
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PROTECH  
300  
001-133  
O
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°F  
GBC Pro-Tech, De Forest, WI 608-246-8844  
MOTOR  
AUTO  
Figure 3-2: Front Control Panel  
Foot Switch/  
Continuous Run  
AUTO/STOP  
1. SPEED ADJUSTMENT – Adjusts the speed of  
the machine from zero to the maximum as the  
control is turned clockwise.  
STOP  
Figure 3-4: Rear Panel Control  
2. MOTION CONTROL  
FORWARD/REVERSE - Controls the  
direction of the drive system, forward, reverse,  
or stop.  
FOOT SWITCH/CONTINUOUS RUN  
AUTO/STOP - Changes control of the machine  
drive from a foot switch to continuous run.  
3. COOLING FANS ON/OFF – Turns the  
cooling fans on or off and turns the vacuum  
table fans on or off, when a vacuum table option  
is installed.  
WARNING  
Use extreme caution when operating the  
laminator with the footswitch. The  
photoelectric eye system is overridden and  
your fingers can get caught in the nip. You  
can be crushed or burned.  
4. UPPER ROLL HEAT ON/OFF – Turns the  
heater controller for the upper main roll on or  
off.  
5. LOWER ROLL HEAT ON/OFF – Turns the  
heater controller for the lower main roll on or  
off.  
6. FOOT SWITCH/CONTINUOUS RUN  
AUTO/STOP - Changes control of the machine  
drive from a foot switch to continuous run.  
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Falcon 36 Operation Manual  
Operation  
should ALWAYS face outward from the  
laminating roll.  
6HWXS  
Setup of the Falcon 36 Laminator is quick and  
straightforward when instructions are followed  
exactly.  
CAUTION  
To adjust the nip, please see Maintenance.  
Always mount the film so that the adhesive  
side faces outward from the laminating roll.  
This prevents hours of roll cleaning.  
Use only the minimum amount of roll pressure  
needed to accomplish the task. While higher  
pressure can make the adhesive bond faster, excess  
pressure can damage the rolls. Wrinkles and bubbles  
have causes that generally cannot be cured by  
applying more pressure.  
2. The film must be centered on the unwind for  
best performance. This is vital when two films  
are fed together. If the two films are not aligned,  
feed problems, wrinkles and other assorted  
troubles will occur.  
CAUTION  
CAUTION  
Excess pressure can damage the laminating  
rolls. Minimum laminator roll pressure is  
consistent with good results.  
Carefully align the two films being fed into  
the nip. If not, you will obtain poor results.  
A typical roll pressure for soft substrates such as  
Foamcore or Orca Board is 1/4 a revolution of the  
laminating roll crank.  
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The following procedure is applicable to both the  
top and bottom feed unwinds.  
A typical roll pressure for hard substrates is 1/2 a  
revolution of the laminating roll crank.  
1. Secure the braking film mount arm so as to  
center the film between the side cabinets.  
A typical roll pressure for encapsulation is 1/2 a  
revolution of the laminating roll crank.  
2. Loosen the core support film mount arm and  
slide it to the drive side of the machine.  
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Film is loaded on the appropriate unwinds. Loading  
and aligning the film are discussed later in this  
section. For applications such as encapsulation, film  
is fed from both the top and bottom feed unwinds.  
3. Install the laminating film onto the braking  
mount arm and slide the core support arm over  
to support the laminating film's end.  
4. Secure the support arm.  
The process of loading and aligning film is the same  
for both the top and the bottom unwinds. There are  
two important points to remember when loading  
film:  
1. The adhesive side of the film must be oriented  
away (on the outside) from the laminating roll.  
Otherwise it will immediately bond to the roll,  
creating a major clean-up project.  
Films have a shiny side and a dull side. The dull  
side is the one with the adhesive. The dull side  
3-3  
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Operation  
Falcon 36 Operation Manual  
Note  
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In the change over from hot to pressure-sensitive  
materials, it is not necessary to return the laminator  
to full cold. With the rolls slightly heated (115 ºF),  
cold films do not exhibit the phenomenon of  
silvering.  
Use the following instructions when heating one or  
both of the laminating rolls. The procedure is the  
same for the top and bottom heaters.  
1. Set the heater switch to ON.  
2. Adjust the temperature controller for the desired  
operating temperature using the temperature  
controller dial adjustment.  
3DSHUꢀ7LSV  
1. Always cut the leading edge of a print straight  
so it can be fed perpendicular to the laminating  
rolls.  
3. When heating the rolls, keep the top roll down  
and turning at a moderate speed to prevent  
uneven heating.  
2. Ink-Jet prints done on high gloss paper might  
not bond or might experience bubbles (called  
puddling). To solve this problem, raise the heat  
setting of the laminator by approximately 20 ºF  
and increase the motor speed by one third.  
4. The temperature controllers have LED (light  
emitting diode) readouts on the rotary dial to  
indicate the status of the heating system. See  
Figure 3-5 to learn about the readouts.  
175  
OUT  
125  
HI  
150  
200  
Red: Set point has  
not been reached  
Solid: Temperature is  
within 5° of set point  
225  
Green: Temperature  
is exactly at set point  
Blinking: Temperature  
is greater than 5° of set  
point  
100  
75  
250  
275  
Off: Set point has been  
reached or exceeded  
50  
PROTECH  
300  
001-133  
Solid: Temperature is  
within 5° of set point  
LO  
°F  
Blinking: Temperature is  
lower than 5° of set point  
Off: Set point has been  
reached or exceeded  
Figure 3-5: Heater Controller  
5. It will take approximately 15 minutes for the  
laminating roll(s) to reach operating  
temperature. When the preset operating  
temperature has been reached, the machine is  
ready to use.  
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The following procedure is the fastest way to cool  
the machine. Natural cooling can also be used.  
1. Set the heater switches to OFF.  
2. Leave the cooling system ON.  
3. Lower the upper main roll until the laminating  
rolls are touching.  
4. Set the Forward/Reverse switch to FWD.  
5. Set the speed control to 2.  
6. Let the machine run until the laminating rolls  
return to room temperature.  
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Falcon 36 Operation Manual  
Operation  
3. Insert Orca board, adhesive side down, in  
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between the rolls. Lower them until they contact  
with the board. Turn the crank another 1/4 of a  
turn. Set the machine to reverse and remove the  
board by activating the motor. Do not adjust the  
roll crank after setting the nip. Reset the  
machine to forward operation.  
Process control charts allow you to record the way  
you thread film through the machine's rolls and  
idlers (called webbing) and the control settings for  
each product and process. Process control charts are  
an excellent tool for training new operators. They  
provide a "road map" for correct machine setup and  
operation.  
4. Web the film by wrapping it around the upper  
film idler and draping it over the upper main  
roll. Have about six inches laying on the infeed  
table.  
This section contains a blank process control chart  
and diagram for the Falcon 36 as well as completed  
charts for the basic operations of the laminator.  
5. With a leader board of the same thickness as the  
mounting board, (make sure the leader board is  
also as wide as the film being used) press the  
footswitch and insert the leader board into the  
nip, square to the rolls. Thin input from the film  
should lay flat on the upper main roll. Stop  
feeding once the back edge of the board is one  
inch from the nip.  
GBC Pro-Tech laminators respond in a very  
accurate and repeatable manner. The charts provide  
a way to set up each time, every time for repeatable  
performance by assuring that all controls are set to  
optimum.  
The process control charts should be kept in this  
manual or in a book close to the laminator. Use the  
machine to encapsulate the popular charts so they  
can withstand food and coffee spills and so they are  
always available for ready reference.  
6. Lay the image onto the adhesive side of the  
Falcon Board. Tacking the image down with a  
tacking iron at this point is sometimes helpful.  
7. Push the Falcon board and image up against the  
leader board and press the footswitch. Be sure to  
maintain paper tension throughout this  
procedure.  
NOTE  
When trying new products and processes, remember  
that  
GBC  
Pro-Tech's  
customer  
service  
representatives are only a phone call away. In North  
America, call 1-800-236-8843.  
8. Once the board is through the nip and it no  
longer continues to feed, disengage the  
footswitch and raise the main roll. With a knife,  
cut the laminate on the infeed side. Pull the  
mounted image through the pull rolls. Do this  
quickly so as to eliminate the possibility of  
getting adhesive on the machine.  
The completed process control charts included in  
this section are based on Falcon Film, Falcon Board,  
and typical prints.  
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NOTE  
You can run more than one image and board during  
a run of this process. Feed one board after another,  
until complete. Make sure that the edge of the board  
being fed into the nip is pushed up against the rear  
edge of the board already in the nip area.  
1. Adjust the machine settings as shown in process  
chart 3-2.  
WARNING  
Do not operate the laminator without the  
infeed table installed on the machine.  
2. Load the film onto the upper unwind assembly.  
3-5  
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Operation  
Falcon 36 Operation Manual  
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This process varies only slightly from the One Pass  
Mount and Laminate process.  
For this process, the image is first encapsulated and  
then mounted.  
1. Adjust the machine settings as shown in process  
chart 3-3.  
1. Adjust the machine settings as shown in process  
chart 3-4a and remove the infeed table.  
2. Insert Falcon Board, adhesive side down, into  
the nip. Lower th upper main roll until it  
2. Web up the overlaminate by bringing it around  
the upper film idler and up to the release paper  
rewind. Tape the film to the rewind and give it  
one full wrap around the rewind tube. Be sure to  
check the process control chart to ensure correct  
web up.  
contacts, and then turn it another 1/4 turn. Press  
the footswitch to remove the board from the nip.  
3. Lay the image onto the adhesive side of the  
Falcon Board. Tacking the image down with a  
tacking iron at this point is sometimes helpful.  
3. With a singe edge razor, cut across the film on  
the rewind tube, being sure not to cut through  
the release liner or the rolls.  
4. Press the footswitch and carefully insert the  
board and image into the nip. Be sure to keep it  
perpendicular to the laminating rolls and  
maintain paper tension throughout the process.  
Note  
WARNING  
Some images will release toner or ink to the upper  
laminating rolls. If this happens, clean immediately  
with alcohol. To prevent this problem, a sheet of  
paper can be used to cover the image during the  
mounting process.  
Use extreme caution when using the single  
edge razor not to damage the rolls or cut  
yourself.  
4. Peel the film back and drape it over the upper  
main roll. To get enough material to do this, it  
may be necessary to turn the rewind tube by  
hand.  
5. Pull the mount film straight up from the lower  
unwind position. Tack it to the laminate. Be  
careful not to stick the film or mount adhesive to  
the machine.  
6. Insert a starter board into the nip and lower the  
upper main roll onto it.  
7. Press the footswitch. Once the leader board is  
through the nip, lower the upper main roll and  
then rotate the crank 1/2 a turn more.  
8. Reinstall the infeed table. You can operate with  
or without the pull rolls at this point.  
9. Encapsulate the images.  
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Falcon 36 Operation Manual  
Operation  
the film to the machine. Tack it to the hot  
overlaminate.  
1. Adjust the machine settings as shown in process  
chart 3-4b.  
4. Insert a starter board into the nip and lower the  
upper main roll onto it.  
2. Trim the print to size and trim the board to the  
size of the print.  
5. Press the footswitch. Once the leader board is  
through the nip, lower the upper main roll and  
then rotate the crank 1/2 a turn more.  
3. Insert the board into the nip area and lower the  
main roll until it contacts. Turn the crank  
another 1/4 of a turn and remove the board using  
the footswitch.  
6. Reinstall the infeed table.  
7. Encapsulate the images.  
4. Clean the board with a tack cloth or cleaning  
roller.  
1. Adjust the machine settings as shown in process  
chart 3-5b.  
5. Place the image face down on a flat surface and  
peel back the release liner on the leading edge  
(about two inches).  
2. Trim the print to size and trim the board to the  
size of the print.  
6. Lay the image on the board and align it  
carefully. When aligned, tack the exposed  
adhesive strip's center to the leading edge to the  
board. Work towards the edges from the center,  
being careful not to wrinkle the image.  
3. Insert the board into the nip area and lower the  
main roll until it contacts. Turn the crank  
another 1/4 of a turn and remove the board using  
the footswitch.  
4. Clean the board with a tack cloth or cleaning  
roller.  
7. Position the piece so that the end with the liner  
peeled back is facing the nip. Insert the first one  
inch of the board into the nip. Very carefully,  
wrap the print back and over the top laminating  
roll, maintaining good print tension throughout  
the mounting process. Be sure that there are no  
wrinkles in the nip area. Carefully peel off the  
liner as the board progresses through the  
laminator.  
5. Place the image face down on a flat surface and  
peel back the release liner on the leading edge  
(about two inches).  
6. Lay the image on the board and align it  
carefully. When aligned, tack the exposed  
adhesive strip's center to the leading edge to the  
board. Work towards the edges from the center,  
being careful not to wrinkle the image.  
8. Trim the board and image to the finished size.  
7. Insert the already mounted portion of the piece  
into the pull roll nip. Lower the upper pull roll  
onto the board and image. Very carefully, wrap  
the print back and over the upper pull roll,  
maintaining good print tension throughout the  
mounting process. Be sure that there are no  
wrinkles in the nip area. Carefully peel off the  
liner as the board progresses through the  
laminator. Be careful not to hit the small lip on  
the fan bridge to avoid damaging the leading  
edge of the mounted image.  
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2YHUODPLQDWHꢍ  
This process is very similar to the Two Pass Mount  
and Laminate using cold overlaminate.  
1. Adjust the machine settings as shown in process  
chart 3-5a and remove the infeed table.  
2. Web up the hot overlaminate by wrapping it  
around the upper film idler and draping it over  
the upper main roll. Drape the film only about  
halfway down the upper main roll.  
8. Trim the board and image to the finished size.  
3. Pull the mount adhesive straight up from the  
lower unwind position, being careful not to stick  
3-7  
GBC Pro-Tech 1997 October  
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Operation  
Falcon 36 Operation Manual  
(QFDSVXODWLRQ  
0DFKLQHꢀ6KXWGRZQ  
This is the most commonly performed process.  
It is very important that the Falcon 36 laminator is  
shut down in proper manner. If not, the laminating  
rolls can be damaged or destroyed.  
1. Adjust the machine settings as shown in process  
chart 3-6 and remove the infeed table. Be sure  
that, while heating the machine, the rolls are  
together and turning.  
CAUTION  
Failure to follow this procedure can result in  
damage to the rolls.  
2. Install laminating film on the upper and lower  
unwinds.  
3. Web up the upper laminate by wrapping it  
around the upper film idler and laying it over the  
upper main roll. Do not drape too much film.  
Too much can fold over and leave a line of glue  
on the roll, thereby affecting image quality.  
1. Turn off the main power to the machine.  
2. Raise the main laminating roll at least one inch.  
3. Put the output roll into the upright position.  
CAUTION  
CAUTION  
Make sure that the adhesive side of the  
laminate is away from the roll to prevent an  
extensive clean up job.  
The laminating and output rolls must always  
be in the up position when the machine is not  
in use.  
4. Web up the lower film by wrapping it around  
the lower film idler and bringing it up to the  
upper main roll. Tack it to the upper laminating  
film.  
5. Insert a leader board into the nip and lower the  
upper main roll. Press the footswitch. Once the  
leader board is through the nip release the  
footswitch. Lower the roll 1/2 a turn past the  
initial contact of the upper laminating roll with  
the lower.  
6. Press the footswitch until the leader board is  
through the pull rolls and lower the upper pull  
roll. Reinstall the infeed table.  
7. Encapsulate the image.  
GBC Pro-Tech 1997 October  
3-8  
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Falcon 36 Operation Manual  
Operation  
352&(66ꢀ&21752/ꢀ&+$57  
MATERIALS  
Image Media  
Mounting Substrate  
LAMINATOR SETTINGS  
Upper Media  
Lower Media  
Top Heater Status  
Bottom Heater Status  
Speed  
Drive Mode  
Pull Roll Position  
Output Cooling  
Main Roll Setting  
Drive Direction  
352&(66ꢀ&21752/ꢀ',$*5$0  
IDENTIFICATION DIAGRAM  
Notes  
___________________________________________________________________________________________  
___________________________________________________________________________________________  
___________________________________________________________________________________________  
3-9  
GBC Pro-Tech 1997 October  
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Operation  
Falcon 36 Operation Manual  
352&(66ꢀ&21752/ꢀ&+$57ꢀꢁꢆꢇ  
One-Pass Mounting and Laminating  
MATERIALS  
3 mil gloss  
N/A  
Bond Paper  
Upper Media  
Lower Media  
Image Media  
Falcon Board  
Mounting Substrate  
LAMINATOR SETTINGS  
ON @ 240 ºF (115 ºC)  
Manual (Footswitch)  
Top Heater Status  
Bottom Heater Status  
Speed  
Drive Mode  
OFF  
1-2 ft/min  
FWD  
UP  
OFF  
Pull Roll Position  
Output Cooling  
Main Roll Setting  
DOWN - 1/4 turn  
Drive Direction  
352&(66ꢀ&21752/ꢀ',$*5$0ꢀꢁꢆꢇ  
Leader  
Board  
Printed  
Image  
FALCON  
Board  
Notes  
___________________________________________________________________________________________  
___________________________________________________________________________________________  
___________________________________________________________________________________________  
GBC Pro-Tech 1997 October  
3-10  
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Falcon 36 Operation Manual  
Operation  
352&(66ꢀ&21752/ꢀ&+$57ꢀꢁꢆꢁ  
One-Pass Mounting  
MATERIALS  
N/A  
N/A  
Bond Paper  
Upper Media  
Lower Media  
Image Media  
Falcon Board  
Mounting Substrate  
LAMINATOR SETTINGS  
ON @ 240 ºF (115 ºC)  
Manual (Footswitch)  
Top Heater Status  
Bottom Heater Status  
Speed  
Drive Mode  
OFF  
2-3 ft/min  
FWD  
UP  
OFF  
Pull Roll Position  
Output Cooling  
Main Roll Setting  
DOWN - 1/4 turn  
Drive Direction  
352&(66ꢀ&21752/ꢀ',$*5$0ꢀꢁꢆꢁ  
Printed  
Image  
FALCON  
Board  
Notes  
___________________________________________________________________________________________  
___________________________________________________________________________________________  
___________________________________________________________________________________________  
3-11  
GBC Pro-Tech 1997 October  
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Operation  
Falcon 36 Operation Manual  
352&(66ꢀ&21752/ꢀ&+$57ꢀꢁꢆꢈD  
Two Pass Mount and Cold/Pressure Overlaminate, First Pass  
MATERIALS  
Pro-Gloss  
Pro-Mount  
Bond Paper  
N/A  
Upper Media  
Lower Media  
Image Media  
Mounting Substrate  
LAMINATOR SETTINGS  
ON @ 110 ºF (43 ºC)  
Manual or Auto  
UP or DOWN  
OFF  
Top Heater Status  
Bottom Heater Status  
Speed  
Drive Mode  
OFF  
4-6 ft/min  
FWD  
Pull Roll Position  
Output Cooling  
Main Roll Setting  
DOWN - 1/2 turn  
Drive Direction  
352&(66ꢀ&21752/ꢀ',$*5$0ꢀꢁꢆꢈD  
Release  
Liner Rewind  
Release Liner  
Notes  
___________________________________________________________________________________________  
___________________________________________________________________________________________  
___________________________________________________________________________________________  
GBC Pro-Tech 1997 October  
3-12  
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Falcon 36 Operation Manual  
Operation  
352&(66ꢀ&21752/ꢀ&+$57ꢀꢁꢆꢈE  
Two Pass Mount and Cold/Pressure Overlaminate, Second Pass  
MATERIALS  
N/A  
N/A  
N/A  
Upper Media  
Lower Media  
Image Media  
Foam Core  
Mounting Substrate  
LAMINATOR SETTINGS  
OFF  
Manual (Footswitch)  
Top Heater Status  
Bottom Heater Status  
Speed  
Drive Mode  
OFF  
2-6 ft/min  
FWD  
UP  
OFF  
Pull Roll Position  
Output Cooling  
Main Roll Setting  
DOWN - 1/4 turn  
Drive Direction  
352&(66ꢀ&21752/ꢀ',$*5$0ꢀꢁꢆꢈE  
Hold Encapsulated  
Image  
Image  
Face  
Release  
Liner  
Notes  
___________________________________________________________________________________________  
___________________________________________________________________________________________  
___________________________________________________________________________________________  
3-13  
GBC Pro-Tech 1997 October  
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Operation  
Falcon 36 Operation Manual  
352&(66ꢀ&21752/ꢀ&+$57ꢀꢁꢆꢉD  
Two Pass Mount and Hot Overlaminate, First Pass  
MATERIALS  
3 mil Gloss  
Pro-Mount  
Bond Paper  
N/A  
Upper Media  
Lower Media  
Image Media  
Mounting Substrate  
LAMINATOR SETTINGS  
ON @ 230 ºF (110 ºC)  
Manual or Auto  
DOWN  
Top Heater Status  
Bottom Heater Status  
Speed  
Drive Mode  
OFF  
3-4 ft/min  
FWD  
Pull Roll Position  
Output Cooling  
Main Roll Setting  
OFF  
DOWN - 1/2 turn  
Drive Direction  
352&(66ꢀ&21752/ꢀ',$*5$0ꢀꢁꢆꢉD  
Notes  
___________________________________________________________________________________________  
___________________________________________________________________________________________  
___________________________________________________________________________________________  
GBC Pro-Tech 1997 October  
3-14  
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Falcon 36 Operation Manual  
Operation  
352&(66ꢀ&21752/ꢀ&+$57ꢀꢁꢆꢉE  
Two Pass Mount and Hot Overlaminate, Second Pass  
MATERIALS  
N/A  
N/A  
N/A  
Upper Media  
Lower Media  
Image Media  
Foam Core  
Mounting Substrate  
LAMINATOR SETTINGS  
OFF  
Manual (Footswitch)  
Top Heater Status  
Bottom Heater Status  
Speed  
Drive Mode  
OFF  
2-3 ft/min  
REV  
DOWN  
OFF  
UP  
Pull Roll Position  
Output Cooling  
Main Roll Setting  
Drive Direction  
352&(66ꢀ&21752/ꢀ',$*5$0ꢀꢁꢆꢉE  
CAUTION: Do not  
allow foam board to  
drop below Fan  
Bridge Lip  
Encapsulated Image  
Release Liner  
Foam Core  
Notes  
___________________________________________________________________________________________  
___________________________________________________________________________________________  
___________________________________________________________________________________________  
3-15  
GBC Pro-Tech 1997 October  
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Operation  
Falcon 36 Operation Manual  
352&(66ꢀ&21752/ꢀ&+$57ꢀꢁꢆꢂ  
Encapsulation  
MATERIALS  
3 mil Gloss  
3 mil Gloss  
Bond Paper  
N/A  
Upper Media  
Lower Media  
Image Media  
Mounting Substrate  
LAMINATOR SETTINGS  
ON @ 230 ºF (110 ºC)  
ON @ 230 ºF (110 ºC)  
3-6 ft/min  
Manual or Auto  
DOWN  
Top Heater Status  
Bottom Heater Status  
Speed  
Drive Mode  
Pull Roll Position  
Output Cooling  
Main Roll Setting  
OFF  
FWD  
DOWN - 1/4 turn  
Drive Direction  
352&(66ꢀ&21752/ꢀ',$*5$0ꢀꢁꢆꢂ  
Notes  
___________________________________________________________________________________________  
___________________________________________________________________________________________  
___________________________________________________________________________________________  
GBC Pro-Tech 1997 October  
3-16  
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Falcon 36 Operation Manual  
Maintenance and Troubleshooting  
Tools required:  
6HFWLRQꢀꢈꢀꢄꢀ0DLQWHQDQFHꢀDQG  
7URXEOHVKRRWLQJ  
•
•
•
1/8" hex wrench  
80% isopropyl alcohol  
100% cotton terry cloth  
Performing regular maintenance on the Falcon 36  
Laminator is critical to the proper operation of the  
machine. A maintenance schedule and a section of  
procedures for disassembling and reassembling the  
serviceable areas of the laminator are included in  
this section.  
CAUTION  
ALWAYS CHECK THE POSITION AND  
CONDITION OF THE THERMOCOUPLES  
PRIOR TO OPERATION! The thermal  
junction of the thermocouples MUST make  
contact with the laminating rolls to maintain  
proper roll operating temperatures. The  
thermocouples must also be free of adhesive  
and dirt. The rolls can overheat and cause a  
fire or seriously damage the laminator.  
Table 6-1: Maintenance Schedule  
Daily  
•
•
•
Clean/adjust the thermocouples  
Clean the rolls  
Inspect the electrical cord for  
damage  
•
Inspect the footswitch cord for  
damage  
Monthly  
•
•
•
Adjust the nip  
Check the chain tension  
WARNING  
Inspect the area around the  
laminator for possible hazards (dust  
buildup, combustible items stored  
too close, etc.)  
Do not attempt to adjust the position of the  
thermocouples if the rolls are hot. You can be  
seriously burned.  
Every  
Six  
Months  
•
•
Lubricate the grease fittings and  
chain  
To adjust a thermocouple:  
Check wire termination tightness  
1. Locate the thermocouple to be adjusted using  
the illustration in Figure 4-3.  
2. Remove the two screws securing the  
thermocouple to the laminator using the 1/8" hex  
wrench and take the thermocouple out.  
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One of the most crucial adjustments to the Falcon 36  
Laminator is positioning the thermocouples and  
making sure they are clean. There are two  
3. Inspect the thermocouple. If there is any  
adhesive or dirt on the thermocouple gently  
clean it off with 80% isopropyl alcohol and a  
cotton terry cloth.  
thermocouples that control the temperature of the  
main rolls. If a thermocouples loses contact with its  
roll, the roll can overheat and be seriously damaged  
or can even start a fire. Therefore, it is absolutely  
critical that both thermocouples be clean and  
positioned properly before operating the laminator  
and it should become second nature to check their  
condition prior to applying power to the laminator.  
GBC Pro-Tech 1997 October  
4-1  
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Maintenance and Troubleshooting  
Falcon 36 Operation Manual  
4. Grasp the aluminum base of the thermocouple  
on either side of the rivets to provide support as  
shown in Figure 4-1. Using your fingers, gently  
bend the thermocouple where the “guitar pick”  
sensor meets the aluminum base.  
Use Your  
Other Hand to  
Gently Bend  
Provide  
Support  
At Rivets  
Figure 4-1: Adjusting the Thermocouple  
Once installed, the critical point of the  
thermocouple MUST make direct contact with  
the roll as shown in Figure 4-2.  
Bend  
Rivets  
Thermal  
Junction  
Roll  
Figure 4-2: Correct Thermocouple Contact  
CAUTION  
Firmly hold the thermocouple where the  
“guitar pick” sensor is riveted to the  
aluminum base while bending. You can  
break the sensor off the base if you do not  
provide this added support.  
5. Replace the thermocouple and tighten the  
screws.  
6. Repeat the procedure for the other  
thermocouple.  
4-2  
GBC Pro-Tech 1997 October  
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Falcon 36 Operation Manual  
Maintenance and Troubleshooting  
Upper Main  
Roll  
Tube to Frame  
Thermocouple  
Wire  
Thermocouple  
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GBC PRO-TECH ENGINEERING, INC.  
DE FOREST  
Model No.  
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WISCONSIN  
Serial No.  
VA  
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Wire Routed  
Through to  
Control Side  
Thermocouple  
Lower Main Roll  
Underside of  
Laminator  
Figure 4-3: Locations of the Thermocouples  
GBC Pro-Tech 1997 October  
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Maintenance and Troubleshooting  
Falcon 36 Operation Manual  
To clean beads of adhesive, dust and dirt from  
the rolls:  
&OHDQLQJ  
1. Allow the laminator to cool slightly to no higher  
than 110ºF (43ºC).  
Tools required:  
•
•
Adhesive coated board  
2. Set the FWD/REV switch to the REV position  
and use the footswitch to move the rolls as you  
clean them. Set the Speed Control to 1.5 ft/min.  
80% isopropyl alcohol (or dishwashing  
detergent)  
•
•
•
Rubber cement eraser  
3. Clean the rolls using a moderate amount of 80%  
isopropyl alcohol on a cotton terry cloth.  
Several 100% cotton terry cloths  
Protective rubber gloves  
CAUTION  
To clean the laminator rolls:  
Use the minimum amount of pressure  
necessary to clean the rolls. You can destroy  
the silicone layer on the rolls by pressing to  
hard or scrubbing too long in one spot.  
1. Remove the infeed table and infeed pressure  
plate to gain access to the rolls.  
WARNING  
Exercise extreme caution while cleaning the  
laminator. You can be caught in the turning  
rolls and crushed or burned.  
WARNING  
Exercise care when cleaning the rolls with  
80% isopropyl alcohol:  
2. While the laminator is at normal operating  
temperature, put on the rubber gloves and, using  
a rubber cement eraser, remove any heat  
activated adhesive from the rolls.  
• Use only in a well ventilated area.  
• Wear rubber gloves.  
• Use only on cool rolls.  
Cleaning heated rolls can ignite the fumes.  
CAUTION  
If silicone adhesive contacts the upper or  
lower roll, remove it IMMEDIATELY using  
a rubber cement eraser. It can harden within  
an hour and ruin the roll.  
CAUTION  
Use only 80% isopropyl alcohol or a rubber  
cement eraser to clean the laminating rolls.  
Harsh chemicals like toluene, acetone or  
MEK destroy the silicone covering of the  
rolls.  
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.  
4. With the laminator rolls no hotter than 110º  
remove dust and dirt from the silicone  
laminating rolls by running an adhesive-coated  
board through the laminator. Be sure to set the  
nip for the thickness of the board used.  
5. Allow the laminator to cool.  
4-4  
GBC Pro-Tech 1997 October  
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Falcon 36 Operation Manual  
Maintenance and Troubleshooting  
To clean the cabinet and covers:  
$GMXVWLQJꢀWKHꢀ1LS  
1. Unplug the laminator to clean the exterior.  
The gap between the two main rolls is called the nip.  
The purpose of adjusting the nip is to ensure  
continuous contact between the laminating rolls as  
the media is drawn through the machine. This  
procedure must be done regularly.  
2. Using a damp cotton terry cloth (water only),  
clean the exterior of the laminator.  
WARNING  
Tools required:  
1/8" hex wrench  
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.  
(2) ¾" open end wrenches  
To adjust the nip:  
CAUTION  
The main rolls must be at room temperature  
to achieve a proper nip setting.  
1. Unplug the laminator and make sure it won’t be  
plugged back in while you are performing this  
procedure.  
2. Remove the drive and control side cabinet  
covers with the 1/8" hex wrench by removing the  
six screws holding each cover in place.  
3. Using the handwheel, lower the upper main roll  
until there is a small gap of light between the  
upper and lower main rolls.  
4. Loosen the jamnut on the nip adjusting bolt on  
each side of the laminator as shown in  
Figure 4-4.  
Adjusting  
Bolt  
Jamnut  
Figure 4-4: Adjusting the Nip  
GBC Pro-Tech 1997 October  
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Maintenance and Troubleshooting  
Falcon 36 Operation Manual  
5. Adjust the nip by turning the adjusting bolt  
using an ¾" open end wrench (clockwise to  
lower the roll end and counter clockwise to raise  
the roll end). Adjust the ends of the upper main  
roll until there is an even gap between the rolls  
as shown in Figure 4-5.  
3. Loosen all four motor mount bolts using the 3/16"  
hex wrench as shown in Figure 4-6. The motor  
should just move freely within the slots.  
1/4" to  
1/2" Play  
Properly Set Nip  
(Distance Between  
Rolls is Equal)  
Loosen Motor  
Mount Bolts  
Figure 4-5: Properly Set Nip  
Downward  
Force Tightens  
Chain  
6. Hold the adjustment bolt in place while  
tightening the jamnut on each side of the  
laminator.  
Figure 4-6: Adjusting the Chain Tension  
4. Using a screwdriver, apply a small amount of  
downward pressure on the motor by prying  
against the inside of the side frame until there is  
¼" to ½" play in the chain.  
7. Replace both cabinet covers and reconnect  
power to the laminator.  
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5. Tighten the mounting bolts while maintaining  
the downward pressure on the motor.  
Adjusting the chain tension on the Falcon 36  
Laminator is a simple procedure that keeps the  
system running smoothly and maximizes the  
efficiency of the motor.  
6. Replace the cabinet cover and reconnect power  
to the laminator.  
Tools required:  
•
•
•
1/8" hex wrench  
3/16" hex wrench  
Screwdriver  
To adjust the chain tension:  
1. Unplug the laminator and make sure it won’t be  
plugged back in while you are performing this  
procedure.  
2. Remove the drive side cabinet cover using the  
1/8" hex wrench by removing the six screws  
holding the cover in place.  
4-6  
GBC Pro-Tech 1997 October  
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Falcon 36 Operation Manual  
Maintenance and Troubleshooting  
/XEULFDWLRQ  
Tools required:  
1
•
•
•
/
8" hex wrench  
W
High temperature grease or lithium grease  
Grease gun  
ARNING  
A
CHTUNG  
MISE EN GARDE  
Grease  
Fittings  
Mo  
ving par  
crush and cut.  
Do not opertastecawnith  
door open.  
C
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To lubricate the laminator:  
WARNING  
Do not lubricate the laminator when it is hot.  
You can be burned.  
WARNING  
Figure 4-7: Grease Fittings  
Unplug the laminator and make sure it won't  
be plugged back in while you are performing  
this procedure. You could be severely  
shocked, electrocuted, or get your fingers  
caught in the drive mechanisms.  
3. Lubricate the chain using a soft cloth and  
automotive oil.  
4. Replace the cabinet covers and reconnect power  
to the laminator.  
1. Remove the drive and control side cabinet  
covers using the 1 8" hex wrench by removing  
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the six screws holding each cover in place.  
For machine parts and technical service:  
2. Using the grease gun, lubricate each grease  
fitting (shown in Figure 4-7) with one squirt of  
high temperature grease.  
North America  
: 1-800-790-7787.  
Europe  
: +44 (0) 1844 202 440  
or fax: +44 (0) 1844 202 441.  
Please provide serial number when calling for  
service.  
For film and application questions:  
North America  
: 1-800-236-8843.  
Europe  
: +44 (0) 1844 202 440  
or fax: +44 (0) 1844 202 441.  
GBC Pro-Tech 1997 October  
4-7  
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Maintenance and Troubleshooting  
Falcon 36 Operation Manual  
4-8  
GBC Pro-Tech 1997 October  
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Falcon 36 Operation Manual  
Maintenance and Troubleshooting  
2XWSXWꢀ7URXEOHVKRRWLQJꢀ*XLGH  
Problem:  
Problem:  
Problem:  
D waves in the image, not in the D waves in the laminate.  
Straight waves in the output.  
laminate.  
Hints:  
• Increase clutch tension.  
• Check roll pressures.  
Hints:  
Hints:  
• Check paper tension.  
• Check relative moisture content • Check nip settings.  
of the paper.  
• Decrease clutch tension.  
• Check operational settings for  
materials being used.  
Other Common  
Problems:  
Feed  
Direction  
Problem:  
Blistering in the image.  
Hints:  
• Increase speed or lower  
the operating  
temperature.  
Problem:  
Coiling of encapsulated  
images.  
Hints:  
• Balance the upper and  
lower unwind brake  
tension. Make sure  
main roll temperatures  
are the same. Adjust  
cooling fans.  
Problem:  
Problem:  
Waves on only one side of the Angled waves on the output.  
output.  
Hints:  
Hints:  
• Check nip settings.  
• Check for even paper tension. • Check for insufficient main roll  
pressure  
• Check for insufficient clutch  
tension.  
Problem:  
Longitudinal waves or  
stuttering, jerking, or  
excessive noise from the  
drive side of the laminator.  
Hints:  
• Increase chain tension,  
decrease unwind brake  
tension.  
GBC Pro-Tech 1997 October  
4-9  
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Maintenance and Troubleshooting  
Falcon 36 Operation Manual  
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4-10  
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Falcon 36 Operation Manual  
Warranty  
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This warranty specifically does not cover:  
GBC Pro-Tech Engineering Company, Inc. warrants  
the equipment sold is free from defects in material  
and workmanship for a period of ninety days (90)  
from the date of delivery to the customer. This  
warranty is the only warranty made by GBC Pro-  
Tech and cannot be modified or amended.  
1. Damage to the laminating rolls 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 casters on even  
surfaces.  
GBC Pro-Tech’s sole and exclusive liability and  
the customer’s sole and exclusive remedy under  
this warranty shall be, at GBC Pro-Tech’s  
option, to repair or replace any such defective  
part or product. These remedies are only  
available if GBC Pro-Tech’s examination of the  
product discloses to GBC Pro-Tech’s satisfaction  
that such defects actually exist and were not  
caused by misuse, neglect, attempt to repair,  
unauthorized alteration or modification,  
Improper use of the machine.  
incorrect line voltage, contaminated air supply,  
or by fire, accident, flood, or other hazard.  
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 ninety day 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 PRO-TECH  
WILL NOT BE LIABLE FOR PROPERTY  
DAMAGE OR PERSONAL INJURY (UNLESS  
PRIMARILY CAUSED BY ITS NEGLIGENCE),  
LOSS OF PROFIT OR OTHER INCIDENTAL OR  
CONSEQUENTIAL DAMAGES ARISING OUT  
OF THE USE OR INABILITY TO USE THE  
EQUIPMENT.  
GBC Pro-Tech 1997 October  
5-1  
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Warranty  
Falcon 36 Operation Manual  
Blank page.  
5-2  
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Falcon 36 Operation Manual  
Technical Information  
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6SHFLILFDWLRQV  
Table 6-1. Falcon 36 Laminator  
Specifications  
Characteristic  
Specifications  
Dimensions  
(L x D x H)  
56" x 31" x 56"  
(1.42 x .79 x 1.42m)  
Weight  
Uncrated: 300 lbs (136 kg)  
Crated : 500 lbs (225 kg)  
Laminating Rolls  
42" (1.06m) roll face with high  
release surface, upper and lower  
rolls internally heated  
Laminating Opening  
Laminating Material  
1.5" (3.8 cm) maximum opening  
controlled with infinitely  
variable hand crank  
Uses heat activated and pressure-  
sensitive materials 0 - 39"  
(99.6 cm) wide on a 3" (7.6 cm)  
ID core, 10" (25.4 cm)  
maximum diameter  
Laminating Speeds  
0 to 18 fmp (o to 5.5 mpm) with  
variable speed, reversible action,  
start and stop controlled either  
through the instrument panel or  
with the footswitch  
Encapsulating Features  
Safety Features  
Pull rolls and cooling fans for  
uniform flat cooling  
•
Photoelectric eye system  
prevents laminating roll  
movement when hands are  
in the nip area  
•
•
All electrical and moving  
mechanical parts are located  
in bolted cabinets  
Hand crank for laminating  
roll movement  
Options  
•
•
•
•
•
Unwind for rolled prints  
Rewind for rolled prints  
Vacuum table  
Outfeed Slitters  
Outfeed Table  
Installation  
Requirement  
220VAC 50 or 60 Hz single  
phase, 30A  
GBC Pro-Tech 1997 October  
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Falcon 36 Operation Manual  
Blank page.  
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Falcon 36 Operation Manual  
Index  
6HFWLRQꢀꢊꢀꢄꢀ,QGH[  
A
L
Accessory pack, 2-4  
Adjusting bolt, 4-5, 4-6  
Laminating material, 6-1  
Laminating opening, 6-1  
Laminating rolls, 6-1  
Laminating speeds, 6-1  
Lubrication, 4-1–4-5  
C
Chain  
Lubrication, 4-7  
Tensioning, 4-6  
Cleaning, 4-4  
Clutch  
M
Main roll  
Lower, 4-5  
Common problems, 4-8  
Controls  
Main rolls, 4-1, 4-5  
Temperature, 4-1  
front control panel, 3-2  
Maintenance schedule, 4-1  
Motor, 2-8, 4-6  
Mounting and laminating (one pass), 3-5  
Mounting only, 3-6  
E
Emergency stop buttons, 1-1, 2-8, 3-1  
Encapsulating, 6-1  
Encapsulation, 3-8  
N
Environment, 2-1  
Nip, 1-1, 1-2, 2-7, 2-8, 3-1, 4-1, 4-4, 4-5, 4-6, 6-1  
Extension cord, 2-1  
O
F
Film  
Outfeed slitters, 6-1  
Outfeed table, 6-1  
loading, 3-3  
positioning, 3-3  
P
Paper, 3-4  
Photoelectric eye, 1-1, 1-2, 2-8, 3-1  
Power cord, 2-2  
Foot bolt, 2-5, 2-6  
Footswitch, 1-1, 1-2, 2-8, 3-1, 4-1, 4-4, 6-1  
FWD/REV switch, 4-4  
Power requirement, 2-1  
Preinstallation checklist, 2-1  
Pressure  
G
Grease fittings, 4-7  
Ground plug, 2-1  
laminator roll, 3-3  
Process control charts, 3-16, 3-5  
H
R
Handwheel, 2-7, 4-5  
Heater, 2-8  
Riggers, 1-3, 2-5, 2-6, 2-7  
Rubber cement eraser, 4-4  
Common problems, 4-8  
Controller, 2-8  
Heating, 3-4  
S
Safety features, 6-1  
Safety information, 1-1  
Safety labels. See Safety information  
Setup, 3-3  
Setup procedure, 2-7–2-8  
Shutdown, 3-8  
I
Infeed table, 4-4  
Installation requirements, 2-1, 6-1  
Isopropyl alcohol, 4-4  
Specifications  
Dimensions, 6-1  
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Index  
Falcon 36 Operation Manual  
Encapsulating, 6-1  
Laminating material, 6-1  
Laminating opening, 6-1  
Laminating rolls, 6-1  
Laminating speeds, 6-1  
Weight, 6-1  
T
Technical support  
Call 1-800-236-8843, 4-7  
thermocouple, 4-1  
Thermocouple, 1-2, 2-7, 2-8, 4-1, 4-2, 4-3  
Locations, 4-3  
Two-pass mount and laminate, 3-6, 3-7  
U
Unpacking, 2-4  
Cardboard box, 2-4  
Crate, 2-6  
Upper main roll, 1-3, 2-7, 4-5, 4-6  
Upper main roll assembly, 2-7  
V
Vacuum table, 6-1  
W
Warnings and cautions. See Safety Information  
Warranty, 5-1  
7-2  
GBC Pro-Tech 1997 October  
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