GBC 930-400 Operation Manual Download

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Falcon 36 Operation Manual

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GBC Pro-Tech 1997 October

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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

Summary of Contents for 930-400

Page 1: ...S SICHERHEITS RICHTL INIEN CONSIGNESDE S CURIT 1 Rea d and und erst and the Ope ratio n Man ual and all safe ty labe ls befo re ope ratin g this mac hine 2 Only a train ed pers on is to be perm itted...

Page 2: ...blication and to the products described in it without notice All specifications and information concerning products are subject to change without notice Reference in this publication to information or...

Page 3: ...ator 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 Moun...

Page 4: ...OL 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...

Page 5: ...accomplish these tasks can vary from negligible to very large The spring system used to provide downward pressure on the top roll is capable of producing forces greater than 1000 pounds 454kg This fo...

Page 6: ...ou or you can be crushed or burned 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 Yo...

Page 7: ...ING 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 dus...

Page 8: ...lectrician 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 WARN...

Page 9: ...1 33 OUT KBIC BARRIER TERMINAL BOARD LINE FUSE ACCEL P N 9884 MAX MIN IR CL ARM FUSE I1 P3 P2 P1 I1 F F L1 L2 A A NOT AUS E M E R G E N CY STOP ARRET D U R G E N C E To be se rv ic ed on ly by tr ai...

Page 10: ...Safety Falcon 36 Operation Manual GBC Pro Tech 1997 October 1 6 Blank page...

Page 11: ...d 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 CAUTION Do not locate the laminator where ai...

Page 12: ...Operation Manual GBC Pro Tech 1997 October 2 2 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 electro...

Page 13: ...con 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 Trimmer 3 x 6 1m x 2m Table Recommended clearance Figure 2 1 Laminator Space Requireme...

Page 14: ...process requires at least two people You can be severely injured or crushed Tools required Phillips head screwdriver 7 8 open end wrench or adjustable wrench If the laminator is in a cardboard box 1 R...

Page 15: ...he 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 CAUTION Do not use a kni...

Page 16: ...e 2 Only a trained person is to be permitt ed to operate this machin e Training should include instruct ion in operatio n under normal conditio ns and emerge ncy situatio ns 3 This machin e is to be s...

Page 17: ...shrink wrap is not recyclable however so it must be discarded NOTE A word about international shipments As these are heavy pieces of equipment GBC Pro Tech takes every precaution to ensure that our la...

Page 18: ...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 c...

Page 19: ...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 overri...

Page 20: ...er 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 sw...

Page 21: ...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 orien...

Page 22: ...as not been reached Green Temperature is exactly at set point Figure 3 5 Heater Controller 5 It will take approximately 15 minutes for the laminating roll s to reach operating temperature When the pre...

Page 23: ...2 Load the film onto the upper unwind assembly 3 Insert Orca board adhesive side down in between the rolls Lower them until they contact with the board Turn the crank another 1 4 of a turn Set the ma...

Page 24: ...encapsulated and then mounted 6HWXS DQG 3URFHGXUH 3DVV 1 Adjust the machine settings as shown in process chart 3 4a and remove the infeed table 2 Web up the overlaminate by bringing it around the upp...

Page 25: ...it over the upper main roll Drape the film only about halfway down the upper main roll 3 Pull the mount adhesive straight up from the lower unwind position being careful not to stick the film to the m...

Page 26: ...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 t...

Page 27: ...ter Status Pull Roll Position Speed Output Cooling Drive Direction Main Roll Setting 352 66 21752 5 0 IDENTIFICATION DIAGRAM Notes _____________________________________________________________________...

Page 28: ...ual Footswitch Bottom Heater Status OFF Pull Roll Position UP Speed 1 2 ft min Output Cooling OFF Drive Direction FWD Main Roll Setting DOWN 1 4 turn 352 66 21752 5 0 Printed Image FALCON Board Leader...

Page 29: ...ootswitch Bottom Heater Status OFF Pull Roll Position UP Speed 2 3 ft min Output Cooling OFF Drive Direction FWD Main Roll Setting DOWN 1 4 turn 352 66 21752 5 0 Printed Image FALCON Board Notes _____...

Page 30: ...Mode Manual or Auto Bottom Heater Status OFF Pull Roll Position UP or DOWN Speed 4 6 ft min Output Cooling OFF Drive Direction FWD Main Roll Setting DOWN 1 2 turn 352 66 21752 5 0 D Release Liner Rew...

Page 31: ...tswitch Bottom Heater Status OFF Pull Roll Position UP Speed 2 6 ft min Output Cooling OFF Drive Direction FWD Main Roll Setting DOWN 1 4 turn 352 66 21752 5 0 E Release Liner Image Face Hold Encapsul...

Page 32: ...230 F 110 C Drive Mode Manual or Auto Bottom Heater Status OFF Pull Roll Position DOWN Speed 3 4 ft min Output Cooling OFF Drive Direction FWD Main Roll Setting DOWN 1 2 turn 352 66 21752 5 0 D Notes...

Page 33: ...OFF Pull Roll Position DOWN Speed 2 3 ft min Output Cooling OFF Drive Direction REV Main Roll Setting UP 352 66 21752 5 0 E Encapsulated Image Release Liner CAUTION Do not allow foam board to drop be...

Page 34: ...e Manual or Auto Bottom Heater Status ON 230 F 110 C Pull Roll Position DOWN Speed 3 6 ft min Output Cooling OFF Drive Direction FWD Main Roll Setting DOWN 1 4 turn 352 66 21752 5 0 Notes ____________...

Page 35: ...ocouples 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 properl...

Page 36: ...ther Hand to Gently Bend 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 Roll Thermal Junction...

Page 37: ...bu rn ha za rd Stay cle ar of mo vin g rol ler s Stop ma ch ine an d rai se rol l be for e cle an ing WARNING ACHTU NG MI SE EN GA RD E NOT AUS E M E R G E N CY STOP ARRET D U R G E N C E NOT AUS E M...

Page 38: ...lls To clean beads of adhesive dust and dirt from the rolls 1 Allow the laminator to cool slightly to no higher than 110 F 43 C 2 Set the FWD REV switch to the REV position and use the footswitch to m...

Page 39: ...contact between the laminating rolls as the media is drawn through the machine This procedure must be done regularly Tools required 1 8 hex wrench 2 open end wrenches To adjust the nip CAUTION The ma...

Page 40: ...othly and maximizes the efficiency of the motor 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 w...

Page 41: ...screws holding each cover in place 2 Using the grease gun lubricate each grease fitting shown in Figure 4 7 with one squirt of high temperature grease 199 4 HCS Inc 800 7 48 02 41 Reor der No 1012 PT...

Page 42: ...Maintenance and Troubleshooting Falcon 36 Operation Manual 4 8 GBC Pro Tech 1997 October...

Page 43: ...em Waves on only one side of the output Hints Check nip settings Check for even paper tension Other Common Problems Problem Blistering in the image Hints Increase speed or lower the operating temperat...

Page 44: ...Maintenance and Troubleshooting Falcon 36 Operation Manual 4 10 GBC Pro Tech 1997 October Blank page...

Page 45: ...arranty 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 rep...

Page 46: ...Warranty Falcon 36 Operation Manual 5 2 GBC Pro Tech 1997 October Blank page...

Page 47: ...vated 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 st...

Page 48: ...Technical Information Falcon 36 Operation Manual 6 2 GBC Pro Tech 1997 October Blank page...

Page 49: ...stallation requirements 2 1 6 1 Isopropyl alcohol 4 4 L Laminating material 6 1 Laminating opening 6 1 Laminating rolls 6 1 Laminating speeds 6 1 Lubrication 4 1 4 5 M Main roll Lower 4 5 Main rolls 4...

Page 50: ...ng 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 b...

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