ILLUSTRATED PARTS

Roller & Heaters Assembly

Idlers & Unwinds Assembly

Roller Housing Asse mbly

Main Roller Lift Assembly

Pull Roller Lift Assembly

Control Panel & Electrical Assembly

Safety Shield & Tables Assembly

Cabinets & Covers Assembly

Rear Slitter Asse mbl y

ELECTRICAL SCHEMATICS

Falcon 60+ (-1) Wire Diagram

Main Board Power Control Unit

Main Board MCU Control Unit

Main Board Sensor Interface Control Unit

Display Board FND/ LED Control Unit

Display Board Key Control Unit

Pressure Detect Control Unit

REVISION SUMMARY

DATE

DWG #

REV.

REASON

BY:

Heater connection wire part numbers added

SNF

PROPRIETARY

GBC CLAIMS PROPRIETARY RIGHTS TO THE

MATERIAL DIS CLO SE D ON THIS D RAWING. I T IS ISSUED I N CO NFIDE NCE

FOR ENGINEERING INFORM ATION ONLY AND SHALL NOT BE REPRODUCED,

COPIED O R DISCLOSED I N WHOLE O R IN PART, O R USED FOR

MANUFACTURE OR FOR ANY OTHER PURPOSE WITHOU T WRITTEN

PERMISSION FROM GBC.

3. 601410706

Cross Bar

2. 860014

Rewind Tube (Not Shown)

1. 601410708

Film Guide

1. 604036229

Guide Table

3. 609070104

Cross Fam Motor

1. 601410695

Sensor Cover

2. 705200201

Infrared Sensor Assembly

1. 601410707

Fan Cover

1. 601410726

Top Heat Sensor Bar

1. 604036227

Front Cover

1. 604036231

Wire Duct

1. 601410727 (601410728)

Sensor Bar Bracket, Left (Right)

This print is the property of G BC. The inf ormati on t hereon is remitte d in confidence.

UNLESS OTHERWISE SPECIFIED

TOLERANCE

DIM. AS

SHOWN

X/X X XX

TOL.

FINISH TO

BE

4151 And erson Road, D eForest, WI 53532

TITLE :

Bridge Assembly GBC Falcon 60 + (-1)

DATE :

ANGLES

+ 1D

DRAWN BY :

DWG SCALE :

DWG :

PROPRIETARY

GBC CLAIMS PROPRIETARY RIGHTS TO THE

MATERIAL DISCLOSED ON THIS DRAWING. IT IS ISSUED IN CONFIDENCE FOR ENGINEERING INFORMATION ONLY AND SHALL NOT BE REPRODUCED,

COPIED OR DISCLOSED IN WHOLE OR IN PART, OR USED FOR

MANUFACTURE OR FOR ANY OTHER PURPOSE WITHOUT WRITTEN PERMISSION FROM GBC. C

(4) 701109350 Stripper Bolt

(4) 607040578 Pull Roller Bushing

(2) 704150111 Thermostat, 120 O C

(2) 613020740 Pull Roller Spring Plate

(2) 613020725 Lock Collar

(1) 601410700 Thermostat Bracket

(4) 701090208 Pull Roller Spring

(2) 613020738 Pull Roller Block

(2) 701010162 Ball Bearing, UR205

(1) 607040578 Pull Roller, Upper

(2) 601410715 Upper Heater Support

(2) 701010160 Ball Bearing, UR210

(2) 613020719 Heat Roller Bearing Block

(4) 613020702 Bearing Block Guide

(4) 613020703 Bearing Spacer, Pull Roller

(1) 607040579 Pull Roller, Driven

(1) 601410714 Heater Support, Lower, Right

(2) 607040577 Main Roller

(1) 601410719 Roller Hole Cover

(1) 601410722 Safety Lock Plate, Right

(2) 704090419 Micro Sensor

(1) 601410724 Safety Switch Plate, Right

(4) 613020704 Bearing Spacer, Heat Roller

(2) 601410725 Switch Plate Bracket

(1) 601410721 Safety Lock Plate, Left

(2) 701020109 Ball Bearing, ULCF210

(1) 701080806 Heat Roller Sprocket, 36T

REVISION

1. 601410723 Safety Switch Plate, Left

CHECKED BY : Sean Flood

1. 601410713 Heater Support, Lower, Left

This print is the property of GBC. The information thereon is remitted in confidence.

UNLESS OTHERWISE SPECIFIED

TOLERANCE

DIM. AS

SHOWN

TOL.

FINISH

TO BE

4151 Anderson Road, DeForest, WI 53532

TITLE :

Roller Housing Assembly GBC Falcon 60 + (-1)

DATE :

ANGLES

+ 1D

DRAWN BY :

DWG SCALE :

DWG :

PROPRIETARY

GBC CLAIMS PROPRIETARY RIGHTS TO THE

MATERIAL DISCLOSED ON THIS DRAWING. IT IS ISSUED IN CONFIDENCE FOR ENGINEERING INFORMATION ONLY AND SHALL NOT BE REPRODUCED,

COPIED OR DISCLOSED IN WHOLE OR IN PART, OR USED FOR

MANUFACTURE OR FOR ANY OTHER PURPOSE WITHOUT WRITTEN PERMISSION FROM GBC. C

(2) 701080808 Lift Sprocker, Gear, 25T

(2) 613020737 Lift Gear Shaft

(2) 613020736 Lift Gear Block

(4) 701060150 Oilless Bushing, SFB1615

(2) 701080814 Idler Helical Gear

(2) 701080815 Lift Helical Gear

(4) 701060152 Oilless Bushing, SFB2015

(2) 701080809 Lift Sprocket, Handle, 24T

(2) 613020735 Lift Gear Block Cover

Right Assembly

2. 701080816 Lift Screw

Left Assembly

This print is the property of GBC. The information thereon is remitted in confidence.

REVISION

CHECKED BY : Sean Flood

UNLESS OTHERWISE SPECIFIED

TOLERANCE

DIM. AS

SHOWN

TOL.

FINISH

TO BE

4151 Anderson Road, DeForest, WI 53532

TITLE :

Pull Roller Lift Assembly GBC Falcon 60 + (-1)

DATE :

ANGLES

+ 1D

DRAWN BY :

DWG SCALE :

DWG :

PROPRIETARY

GBC CLAIMS PROPRIETARY RIGHTS TO THE

MATERIAL DISCLOSED ON THIS DRAWING. IT IS ISSUED IN CONFIDENCE FOR ENGINEERING INFORMATION ONLY AND SHALL NOT BE REPRODUCED,

COPIED OR DISCLOSED IN WHOLE OR IN PART, OR USED FOR

MANUFACTURE OR FOR ANY OTHER PURPOSE WITHOUT WRITTEN PERMISSION FROM GBC. C

Upper Assembly

1. 703070375 Grill Knob

Lower Assembly

(2) 613020756 Tension Wheel

(1) 613020759 Unwind Clevis, Upper, Lower Unwinds

(3) 613020760 Unwind Clevis, Upper

(3) 613020755 Tension Washer

(3) 613020716 Film Shaft Brake Block

(3) 613020769 Film Shaft

(3) 613020706 Brake Block, Upper

(3) 613020715 Film Pipe Collar

(6) 613020717 Film Shaft Bushing

(3) 613020705 Brake Block, Lower

(3) 613020714 Film Center Support

(3) 701110717 Thrust Needle Roller Bearing Washer, AS5578

(2) 613020758 Unwind Clevis, Lower, Lower Unwinds

(6) 706111098 Film Core Assembly

This print is the property of GBC. The information thereon is remitted in confidence.

REVISION

CHECKED BY : Sean Flood

UNLESS OTHERWISE SPECIFIED

TOLERANCE

DIM. AS

SHOWN

TOL.

FINISH

TO BE

4151 Anderson Road, DeForest, WI 53532

TITLE :

Unwind Brake Assembly GBC Falcon 60 + (-1)

DATE :

ANGLES

+ 1D

DRAWN BY :

DWG SCALE :

DWG :

TECHNICAL SERVICE & SUPPORT BULLETIN

T.S.S.B. NO.

MODEL:

VARIOUS MODELS

SUBJECT:

HEATER WIRES WITHOUT BRASS

CONNECTORS

DATE: 10/12/05

PAGE: 1 Of 1

Here is a list of part numbers for heater wires without brass connectors for various laminators. The brass connectors are separate from the heater wires. When ordering heater wires you will need to order the brass connectors under part number 637500017.

P/N# 638001093, Required Qty (2) right side for Orca 64 (Top & Bottom) P/N# 638001097, Required Qty (2) left side for Orca 64 (Top & Bottom)

P/N# 638001093, Required Qty (1) right side for Orca 64-TH (Top) P/N# 638001097, Required Qty (1) left side for Orca 64-TH (Top)

P/N# 638001097, Required Qty (2) left side for Falcon 60+ (Top & Bottom) P/N# 638001697, Required Qty (2) right side for Falcon 60+ (Top & Bottom)

P/N# 638001697, Required Qty (1) right side for Talon 44 & 64 (Top) P/N# 638001698, Required Qty (1) right side for Talon 44 & 64 (Bottom) P/N# 638001705, Required Qty (2) left side for Talon 44 & 64 (Top & Bottom)

P/N# 638001697, Required Qty (1) right side for Talon 80 (Top) P/N# 638001705, Required Qty (1) left side for Talon 80 (Top)

P/N# 638001093, Required Qty (2) right side for Titan 110/165 (Top & Bottom) P/N# 638001097, Required Qty (2) left side for Titan 110/165 (Top & Bottom)

NOTE: When you order heater wires, you have to order the brass connectors under part number 637500017. The brass connectors can be crimped on the heater wires by using a standard wire crimping tool. The heater wire and brass connector can now be attached onto the end of the heater.

500 Bond Street • Lincolnshire, IL 60069 • ph 800-723-4000 • fax 888-821-3736 • www.gbc.com

TECHNICAL SERVICE & SUPPORT BULLETIN

T.S.S.B. NO.

MODEL:

FALCON 60+ -1

SUBJECT:

ELECTRONIC UPGRADE KIT

DATE: 8/24/05

PAGE: 1 Of 12

GBC Engineering Team has released an Electronic Upgrade Kit, part number 005177 that must be installed on all Falcon 60+ -1’s that experience Main P.C. Board or Motor Driver Board failures. This Kit is intended to replace and protect these boards from motor failure utilizing a “Dynamic Brake System”. When you order the Electrical Upgrade Kit, you will receive all necessary electrical components and installation instructions.

NOTE: The Main P.C. Board with Rev 3.2.0 Chip has been modified to only work with this kit. If you install the Main P.C. Board without having the Upgrade Kit installed, it will not work. This holds true for the Motor Driver Board as well, due to rewiring that is required. There is no change to the EMO/ Relay Board part number 706011741.

This is not a mandatory Upgrade Kit, due to the fact that there are machines that have not experienced any board failures. Contact your Regional Manager to determine if the customer should be charged, depending on the amount of Motor Driver Board failures or Main P.C. Board failures on each individual machine.

After you have installed the Electrical Upgrade Kit if the Main P.C. Board or the Motor Driver Board becomes defective, you can replace the individual boards. The part number for the modified Main P.C. Board with Rev 3.2.0 Chip is 706011724. Part number for the Motor Driver Board is 638900267. These will be the same boards that were in the Kit.

The following pages contain the installation instructions for future reference. Please update your F60+ (-1) Operator/Parts Manual, P/N# 1722885 with this information.

Falcon 60+ Electronic Upgrade Kit. Part Number 005-177

Remove electrical side cover and electrical protective cover.

Remove the 18VAC plug from the main PCB. Remove the blue wires going to the fuse 250V 3.15 Amp.

Remove and discard wires from the Bridge Rectifier. The Bridge Rectifier can be removed and discarded as well.

Disconnect main AC from Transformer. (Black wires, female plug, coming from Main AC Terminal Block.

Completely remove the Transformer. The Transformer can be discarded at this time.

Locate Main Motor Driver PCB. Unplug DC plug from board. Completely remove Black and Red DC wire and discard.

Locate Relay PCB. Locate port CN5/TO_MOTOR. Unplug from Relay Board and label “Motor”. Leave labeled Motor wire hang for now.

Mount power supplies on mounting bracket. Make sure that the 24VDC Power supply is on the top left and the 48VDC one is on the bottom right of the mounting bracket. The In/output side of the Power Supply should be orientated to the right.

Locate Brown and Blue wires from kit labeled “Main AC”. Insert the Male Plug into the Female AC plug. The Female Plug should have two Black wires going into the plug and connect to the Main AC Terminal block.

Locate the remaining four wires. Two will be Blue and two will be Brown. Take the longest Brown and the longest Blue and connect them to the 24VDC Power Supply. Brown connects to position “N” Blue connects to position “L”

The remaining two wires get connected to the 48VDC Power Supply. Brown connects to position “N” Blue connects to position “L” Ground the Power Supplies to the main chassis. Complete this step by mounting the Power Supplies to the Side frame.

Locate the Red and Black wires in kit. They will be labeled “DC Power Supply Wires”. Locate Position LAMP_POR on Main PCB. Remove plug occupying LAMP_POR. Insert new Male plug from kit labeled LAMP_PO.

Locate the remaining Female plug. Connect it with the plug we just removed from the LAMP_POR.

Locate the two Blue connectors joining three wires together. Insert the Red group into the Phoenix Relay, Position A1.

Insert the Black group into the Phoenix Relay, Position A2.

Connect the short Red wire in the group into the Phoenix Relay, position #11.

Connect the short Black wire from the group to the Omron Relay, Position #14.

Connect the remaining Black and Red wires to the 24VDC Power Supply. Red Wire to V+ Black Wire to V-

Locate the 48VDC Red and Black Power Supply wires. Connect the male plug into the Main Motor Driver board, position CN2/DC. Connect the other ends to the 48VDC Power Supply. Red Wire to V+ Black Wire to V-

Locate Red 8 inch, 22-gauge wire from kit. Connect one end to the Phoenix Relay, position #11. Connect the other end to the Omron Relay, position #13.

Locate CN5 14-gauge wire from the kit. (Black & Red with Male Plug). Insert Male plug into Main Relay Board, position CN2/TO_MOTOR. Connect the Black wire to the Omron Relay, position #5.

Connect the Red wire to the Omron Relay, position #8.

Locate the Red and Black Motor wire from the kit. Connect the Female plug directly to the Motor. Wire from Motor should be hanging. (See step #7). Connect the Black wire to the Omron Relay , position # 9. Connect the Red wire to the Omron Relay, position #12.

Locate the Power Resistor. Connect one side of the Resistor to the Omron Relay, position #1. Connect the other side to the Omron Relay, position #4.

Locate main PCB, position SIG. Remove entire cable inserted in position SIG. Replace with Signal Wire provided in kit. One end to Motor Driver position SIG. One end to Main PCB, position ROL_SIG.

Locate the remaining wires of f of cable. One will be Red, one will be green. Connect the Red wire to the Phoenix Relay, position B. Connect the Green wire to the Phoenix Relay, position A2.

Locate Spiral Wrap provided in kit. Wrap wires to prevent brake wheel from wearing on the wires.

(RED)

(WHT)

(GRN)

EXPLODED VIEW

ROL_SIG

MAIN BOARD

POWER

YELLOW WIRE

YELLOW WIRE

To Original Lamp Male Plug

FEMALE PLUG

TO PLUG ON MAIN MOTOR

RED WIRE

BLACK WIRE

PHEONIX

CONTACT RELAY

OMRON

RELAY

How To Retrofit F60+

KIT # 005-177

BLACK WIRE

RED WIRE

CN5 To_Motor

Main Relay Board

BLACK WIRE

RED WIRE

RED WIRE

BLACK WIRE

BLACK WIRE

BLACK WIRE

48V DC Power Supply

TO GROUND

TO GROUND

MALE PLUG

FEMALE PLUG

To AC Main Terminal Block.

BLUE WIRE

24V DC Power Supply

BROWN WIRE

GREEN WIRE

RED WIRE

Motor Drive Board

FUSE

SIGNAL

3 WIRE SHIELDED

CABLE

BLACK WIRE

RED WIRE

RED WIRE

POWER

MOTOR

RED WIRE

RED WIRE

GREEN WIRE

RED WIRE

MALE PLUG

To Main Board LAMP_POR

BLACK WIRE

3 WIRE SHIELDED

CABLE

BLACK WIRE

TO FUSE

RED WIRE

Falcon 60+ Electronic Upgrade Kit #005-177 Wire Assembly Assembly #280-106

AC Supply-

• 19 Inch Brown 22 Gauge
• 19 Inch Blue 22 Gauge
• 5 Inch Brown
• 5 Inch Blue

#6 Fork #6 Fork #8 Fork #8 Fork

Lamp-

250 Female 250 Female 250 Male 250 Male #6 Fork #6 Fork #6 Farro #6 Farro

30.5 Inch Red 22 Gauge 30.5 Inch Black 22 Gauge 6 Inch Red 22 Gauge 6 Inch Black 22 Gauge 28 Inch Red 22 Gauge 28 Inch Black 22 Gauge 8 Inch Red 22 Gauge 8 Inch Black 22 Gauge

48VDC-

• 23 Inch Red 22 Gauge
• 23 Inch Black 22 Gauge

#6 Fork #6 Fork

Relay Jumper-

• 8 Inch Red 22 Gauge

CN5 Motor-

• 10 Inch Red 14 Gauge
• 10 Inch Black 14 Gauge

#6 Fork-250 Male #6 Fork-250 Male

Motor-

• 16 Inch Red 14 Gauge
• 16 Inch Black 14 Gauge

#6 Fork-250 Female #6 Fork-250 Female

Grounds-

• 23 Inch 14 Gauge Green/Yellow
• 23 Inch 14 Gauge Green/Yellow

#10 Ring X 2 #10 Ring X 2

Resistor-

• 9 Inch Yellow 22 Gauge
• 9 Inch Yellow 22 Gauge

#6 Fork #6 Fork

Signal Wire-

• 3C, Red, Green, White.24 Inch.