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GBC 930-400 manual

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Table of contents for the manual

  • Page 1

    )DOFRQ2SHUDWLRQ 0DQXDO © 1997 GBC Pro-T ech Do not duplicate without w ritten permission © 1 9 9 4 H C S , I n c . 8 0 0 - 7 4 8 - 0 2 4 1 R e o r d e r N o . 1 0 3 3 R - P T Crush and burn hazard. Stay clear of moving rollers. Stop machine and raise roll before cleaning. WARNING ACHTUNG MISE EN GARDE © 1 9 9 4 H C S , In c . 8 0 0 -[...]

  • Page 2

    Falcon 36 Operation Manual ii  GBC Pro-Tech 1997 October The information in this publication is pr ovided for reference and is believed to be accurate and complete. GBC Pr o-Tech is not li able for err ors in thi s publicati on or for incidental or consequenti al damage in connection w ith the furni shing or use of the informat ion in this publ [...]

  • Page 3

    Falcon 36 Operation Manual  GBC Pro-Tech 1997 October iii 7DEOHRI&RQWHQWV 6HFWLR Q6D IHW ?[...]

  • Page 4

    Falcon 36 Operation Manual iv  GBC Pro-Tech 1997 October Procedure ...................................................................................................................... ... 3-8 PROCESS CONTROL CHART............................................................................................ 3-9 PROCESS CONTROL DIAGRAM ...........[...]

  • Page 5

    Falcon 36 L ami nator Servi ce Man u al Safety and W arran ty I nformati on  GBC Pro-Tech 1997 October 1-1 6HFWLRQ 6DIHW DO NOT ATTEM PT TO OPERATE Y OUR FALCON 36 LAMINATOR UNTIL YO U HAVE READ THI S SECTION CAREFULLY! Your safety, as w ell as the safety of others, is important to GBC Pro- Tech. This section contains important s[...]

  • Page 6

    Safety and Warran ty Info rmation Fal co n 36 Lami n ato r Service Manu al  GBC Pro-Tech 1997 October 1-2 NO T A U S E M E R G E N C Y S T OP A R R E T D ' U R G E N C E NO T A U S E M E R G E N C Y S T OP A R R E T D ' U R G E N C E T wist and pull up both buttons to resume operation Push either button to stop the laminator 1 / 4 t u [...]

  • Page 7

    Falcon 36 L ami nator Servi ce Man u al Safety and W arran ty I nformati on  GBC Pro-Tech 1997 October 1-3 WARNING Exercise care when cleaning the rolls with 80% isopropyl alcohol: • Use only in a well ventilated area. • Wear rubber gloves. • Use only on cool rolls. Cleaning heated rolls can ignite the fumes. CAUTION Use only 80% isopropyl[...]

  • Page 8

    Safety and Warran ty Info rmation Fal co n 36 Lami n ato r Service Manu al  GBC Pro-Tech 1997 October 1-4 WARNING Connect the lamin ator 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 de[...]

  • Page 9

    Falcon 36 Operation Manual Safety  GBC Pro-Tech 1997 October 1-5 © 1 9 9 4 H C S , In c . 8 0 0 -7 4 8 -0 2 4 1 R e o rd e r N o .1 0 3 3 R -P T Crush and burn hazard. Stay clear of moving rollers. Stop machine and raise roll before cleaning. WARNING ACHTUNG MISE EN GARDE ©1994 HCS, Inc. 800-748-0241 Reorder No.1033-PT Crush and burn hazard. S[...]

  • Page 10

    Safety Falcon 36 Operation Manual  GBC Pro-Tech 1997 October 1-6 Bl an k pa ge.[...]

  • Page 11

    Falcon 36 Operation Manual Installation  GBC Pro-Tech 1997 October 2-1 6HFWLRQ ,QVWDOOD WLRQ Before a Falcon 36 Laminator can be installed there are a few requirem ents that must be m et. Make certain that each of the requirements listed in the following preinstallation check list are m et before beginning installation. CAUTION Fa[...]

  • Page 12

    Installation Falcon 36 Operation Manual  GBC Pro-Tech 1997 October 2-2 WARNING Do not allow anything to rest on the pow er cord. Do not locate the cord where people can walk on it. You or others can be severely shocked, electrocuted or cause a fire.[...]

  • Page 13

    Falcon 36 Operation Manual Installation  GBC Pro-Tech 1997 October 2-3 4'6" (~1.1m) 2'2" (~.7m) 10' (~3m) 10' (~3m) 3' (~1m) 73" (~1.8m) Floor T rimmer 3' x 6' (~1m x 2m) T able Recommended clearance Figure 2-1: Laminator Space Requi rements[...]

  • Page 14

    Installation Falcon 36 Operation Manual  GBC Pro-Tech 1997 October 2-4 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[...]

  • Page 15

    Falcon 36 Operation Manual Installation  GBC Pro-Tech 1997 October 2-5 Foot Bolt Shipping Pad Figure 2-3: Removing the Packing Assemblies 5. Remov e the screws holding the foot pads onto the pallet using the Phillips head screw driver. 6. Have the lam inator lifted off the skid and placed on the floor by licensed rig gers. The rigg ers must also[...]

  • Page 16

    Installation Falcon 36 Operation Manual  GBC Pro-Tech 1997 October 2-6 If the laminator is in a crate: 1. Rem ove the top of the crate and then the sides in the order shown in Figure 2- 4. CAUTION Do not allow the top to fall into the crate. It can damage the laminator. Do not put packing screws on the f loor. They can cause problems when trying[...]

  • Page 17

    Falcon 36 Operation Manual Installation  GBC Pro-Tech 1997 October 2-7 WARNING Do not attempt to move th e laminator across anything other than a flat, level surf ace wit hout trained and quali fi ed 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 LI CEN[...]

  • Page 18

    Installation Falcon 36 Operation Manual  GBC Pro-Tech 1997 October 2-8 WARNING ALWAYS CHECK THE P OSITI ON AND CONDITIO N OF THE TH ERMOCO UPLES PRIOR TO OPERA TION! 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[...]

  • Page 19

    Falcon 36 Operation Manual Operation  GBC Pro-Tech 1997 October 3-1 6HFWLRQ 2SHU DWLRQ 6DIHW GBC Pro- Tech laminators are pow erful machines that are designed to m ount, lam inate and encapsulate. The forces required to accomplish these tasks can v ary from neglig ible to very larg e. The spring system used to provide dow nward p[...]

  • Page 20

    Operation Falcon 36 Operation Manual  GBC Pro-Tech 1997 October 3-2 2SHUDWRU &RQWURO V 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 nam es and functions of these controls are as follows: MOTO R FWD REV SPEED STOP AUT O F ANS POWER HEA TERS T O P[...]

  • Page 21

    Falcon 36 Operation Manual Operation  GBC Pro-Tech 1997 October 3-3 6HWXS Setup of the Falcon 36 Laminator is quick and straightforward w hen instructions are followed exactly. To adjust the nip, please see Maintenance . Use only the m inim um am ount of roll pressure needed to accomplish the task . While higher pressure can mak e the adhesive b[...]

  • Page 22

    Operation Falcon 36 Operation Manual  GBC Pro-Tech 1997 October 3-4 +HDWLQ J 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 temp erature controller for the desired operating tem perature using the tem peratur[...]

  • Page 23

    Falcon 36 Operation Manual Operation  GBC Pro-Tech 1997 October 3-5 3URFHVV&RQWU RO&KDUWV Process control charts allow you to record the w ay you thread film through the m achine' s rolls and idlers (called webbing) and the control setting s for each product and process. Process control charts are an excellent tool for trainin[...]

  • Page 24

    Operation Falcon 36 Operation Manual  GBC Pro-Tech 1997 October 3-6 0RXQWLQJ2QO This process varies only slig htly from the One Pass Mount and Laminate process. 1. Adjust the machine setting s as shown in process chart 3-3. 2. Insert Falcon Board, adhesiv e side down, into the nip. Lower th upper m ain roll until it contacts, and then turn [...]

  • Page 25

    Falcon 36 Operation Manual Operation  GBC Pro-Tech 1997 October 3-7 1. Adjust the machine setting s as shown in process chart 3-4b. 2. Trim the print to siz e and trim the board to the size of the print. 3. Insert the board into the nip area and low er the main roll until it contacts. Turn the crank another 1/4 of a turn and remov e the board us[...]

  • Page 26

    Operation Falcon 36 Operation Manual  GBC Pro-Tech 1997 October 3-8 (QFDSVXODWLRQ This is the most com m only perform ed process. 1. Adjust the machine setting s as shown in process chart 3-6 and rem ov e the infeed table. Be sure that, while heating the m achine, the rolls are together and turning . 2. Install lam inating film on the upper and [...]

  • Page 27

    Falcon 36 Operation Manual Operation  GBC Pro-Tech 1997 October 3-9 352&(66&21752/&+$57 MA T ERIA LS Upper Media Image Media Low er Media Mounting Subst rat e LA M INAT OR SETTINGS Top Heater Status Drive Mode Bottom Heater St at us Pull Roll Positi on Speed Output Cool i ng Drive Direction Main Roll Set ting 352&(66&[...]

  • Page 28

    Operation Falcon 36 Operation Manual  GBC Pro-Tech 1997 October 3-10 352&(66&21752/&+$57 One-Pass Mounting and Laminating MA TERIA LS Upper Media 3 mil gloss Image Medi a Bond Paper Low er Media N/A Mounti ng Substrate Falcon Board LA M INAT OR SETTINGS Top Heater Status ON @ 240 ºF (115 º C) Drive Mode Manual (Fo[...]

  • Page 29

    Falcon 36 Operation Manual Operation  GBC Pro-Tech 1997 October 3-11 352&(66&21752/&+$57 One-Pass Mounting MA TERIA LS Upper Media N/A Image M edi a Bond Paper Low er Media N/A Mounti ng Substrate Falcon Board LA M INAT OR SETTINGS Top Heater Status ON @ 240 ºF (115 º C) Drive Mode Manual (Footswitch) Bottom Heate[...]

  • Page 30

    Operation Falcon 36 Operation Manual  GBC Pro-Tech 1997 October 3-12 352&(66&21752/&+$57D Two Pass Mount and Cold/Pressure Ov erlaminate, First Pass MA TERIA LS Upper Media Pro-Gloss I mage M edia Bond Paper Low er Media Pro-Mount Mounting Subst rat e N/A LA M INAT OR SETTINGS Top Heater Status ON @ 110 ºF (43 º C[...]

  • Page 31

    Falcon 36 Operation Manual Operation  GBC Pro-Tech 1997 October 3-13 352&(66&21752/&+$57E Two Pass Mount and Cold/Pressure Ov erlaminate, Second Pass MA TERIA LS Upper Media N/A Image M edi a N/A Low er Media N/A Mounti ng Substrate Foam Core LA M INAT OR SETTINGS Top Heater Status OFF Drive Mode M anual (Footswitch[...]

  • Page 32

    Operation Falcon 36 Operation Manual  GBC Pro-Tech 1997 October 3-14 352&(66&21752/&+$57D Two Pass Mount and Hot Ov erlaminate, First Pass MA TERIA LS Upper Media 3 mil Gloss Image Medi a Bond Paper Low er Media Pro-Mount Mounting Subst rat e N/A LA M INAT OR SETTINGS Top Heater Status ON @ 230 ºF (110 º C) Drive [...]

  • Page 33

    Falcon 36 Operation Manual Operation  GBC Pro-Tech 1997 October 3-15 352&(66&21752/&+$57E Two Pass Mount and Hot Ov erlaminate, Second Pass MA TERIA LS Upper Media N/A Image M edi a N/A Low er Media N/A Mounti ng Substrate Foam Core LA M INAT OR SETTINGS Top Heater Status OFF Drive Mode M anual (Footswitch) Bottom H[...]

  • Page 34

    Operation Falcon 36 Operation Manual  GBC Pro-Tech 1997 October 3-16 352&(66&21752/&+$57 Encapsulation MA TERIA LS Upper Media 3 mil Gloss Image Medi a Bond Paper Low er Media 3 mil Gloss Mounting Subst rat e N/A LA M INAT OR SETTINGS Top Heater Status ON @ 230 ºF (110 º C) Drive Mode Manual or Auto Bottom Heater [...]

  • Page 35

    Falcon 36 Operation Manual Maintenance and Troubleshooting  GBC Pro-Tech 1997 October 4-1 6HFWLRQ 0DLQWHQDQFHDQG 7 U RXEOHVKRRWLQJ Perform ing regular m aintenance 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 [...]

  • Page 36

    Maintenance and Troubleshooting Falcon 36 Operation Manual 4-2  GBC Pro-Tech 1997 Oct ober 4. Grasp the alum inum base of the therm ocouple on either side of the rivets to prov ide support as shown in Figure 4- 1. Using y our fingers, gently bend the thermocouple where the “g uitar pick” sensor meets the alum inum base. Provide Support At Ri[...]

  • Page 37

    Falcon 36 Operation Manual Maintenance and Troubleshooting  GBC Pro-Tech 1997 October 4-3 NOT A U S E M E R G E N C Y S T OP A R R E T D ' U R G E N C E © 1994 H CS, Inc. 800-748-0241 Reorder No.1033R-PT Crush and burn hazard. Stay clear of m oving rollers. Stop m achine and raise roll before cleaning. WARNING ACHTUNG MISE EN GARDE ©1994 [...]

  • Page 38

    Maintenance and Troubleshooting Falcon 36 Operation Manual 4-4  GBC Pro-Tech 1997 Oct ober &OHDQLQJ Tools required: • Adhesiv e coated board • 80% isopropyl alcohol (or dishwashing detergent) • Rubber cement eraser • Several 100% cotton terry cloths • Protective rubber g loves To clean the laminator rolls: 1. Rem ove the infeed tab[...]

  • Page 39

    Falcon 36 Operation Manual Maintenance and Troubleshooting  GBC Pro-Tech 1997 October 4-5 To clean the cabinet and covers: 1. Unplug the lam inator to clean the exterior. 2. Using a dam p cotton terry cloth (water only ), clean the exterior of the laminator. WARNING Do not use liquid or aerosol cleaners on the laminator. Do not sp ill liquid of [...]

  • Page 40

    Maintenance and Troubleshooting Falcon 36 Operation Manual 4-6  GBC Pro-Tech 1997 Oct ober 5. Adjust the nip by turning the adjusting bolt using an ¾" open end wrench (clock wise 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 g ap between the rolls as shown [...]

  • Page 41

    Falcon 36 Operation Manual Maintenance and Troubleshooting  GBC Pro-Tech 1997 October 4-7 /XEULFDW LRQ Tools required: • 1 / 8 " hex wrench • High tem perature grease or lithium g rease • Grease gu n To lubricate th e laminator: WARNING Do not lu bricate the laminator when it is hot. You can be burned. WARNING Unplug the laminat or an[...]

  • Page 42

    Maintenance and Troubleshooting Falcon 36 Operation Manual 4-8  GBC Pro-Tech 1997 Oct ober[...]

  • Page 43

    Falcon 36 Operation Manual Maintenance and Troubleshooting  GBC Pro-Tech 1997 October 4-9 2XWSXW7 URXEOHVKRRWLQJ *XLGH Problem: D waves in the image, not in the laminate. Hints: • Check paper tension. • Check relative moisture content of the paper . Problem: D waves in the laminate. Hints: • Increase clutch tension. • Check roll pr[...]

  • Page 44

    Maintenance and Troubleshooting Falcon 36 Operation Manual 4-10  GBC Pro-Tech 1997 Oct ober Bl an k pa ge.[...]

  • Page 45

    Falcon 36 Operation Manual Warranty  GBC Pro-Tech 1997 October 5-1 6HFWLRQ : DU U DQW /LPLW HG:DUUDQW GBC Pro- T ech Engineering Com pany, Inc. w arrants the equipment sold is free from defects in material and workm anship for a period of ninety day s (90) from the date of delivery to the customer. This warranty is the only [...]

  • Page 46

    Warranty Falcon 36 Operation Manual 5-2  GBC Pro-Tech 1997 Oct ober Bl an k pa ge.[...]

  • Page 47

    Falcon 36 Operation Manual Technical Information  GBC Pro-Tech 1997 October 6-1 6HFWLRQ 7 HF KQLFDO,QIRU PDWLRQ 6SHFLILFDWL RQV Table 6-1. Falcon 36 Laminat or Specification s 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 [...]

  • Page 48

    Technical Information Falcon 36 Operation Manual 6-2  GBC Pro-Tech 1997 Oct ober Bl an k pa ge.[...]

  • Page 49

    Falcon 36 Operation Manual Index  GBC Pro-Tech 1997 October 7-1 6HFWLRQ ,QGH [ A Accessory pack, 2-4 Adjusting bolt, 4-5, 4-6 C Chain Lubric ation, 4-7 Tens ioning, 4-6 Cleanin g, 4- 4 Clutch Com mon proble ms, 4-8 Controls front c ontrol panel, 3-2 E Eme rgenc y st op buttons, 1-1, 2-8, 3-1 Encapsulating, 6-1 Encapsulation, 3-8 E[...]

  • Page 50

    Index Falcon 36 Operation Manual 7-2  GBC Pro-Tech 1997 Oct ober Encapsulating, 6-1 Lam inating mate rial, 6-1 Lam inating opening , 6-1 Lam inating rolls, 6-1 Laminating speeds, 6-1 Weig ht, 6-1 T Tec hnical s upport Call 1-800- 236-8843, 4-7 therm ocouple, 4-1 Ther mocouple , 1-2, 2-7, 2-8, 4-1, 4-2, 4-3 Loca tions, 4-3 Tw o-pass m ount and la[...]