FALCON 60+ (-1) Parts List_1_PARTS.pdfILLUSTRATED PARTS F60+1 - 001 Bridge Assembly F60+1 - 002 Roller & Heaters Assembly F60+1 - 003 Idlers & Unwinds Assembly F60+1 - 004 Drive Assembly

FALCON 60+ (-1) Parts List

GBC IS AN ACCO BRANDS COMPANY

Illustrated Parts

Electrical Schematics

GBC FALCON 60+ (-1)ILLUSTRATED PARTS

AND SCHEMATICS BOOK

07/07/03

ILLUSTRATED PARTSF60+1 - 001 Bridge Assembly

F60+1 - 002 Roller & Heaters Assembly

F60+1 - 003 Idlers & Unwinds Assembly

F60+1 - 004 Drive Assembly

F60+1 - 005 Roller Housing Assembly

F60+1 - 006 Main Roller Lift Assembly

F60+1 - 007 Pull Roller Lift Assembly

F60+1 - 008 Clutch Assembly

F60+1 - 009 Unwind Brake Assembly

F60+1 - 010 Control Panel & Electrical Assembly

F60+1 - 011 Safety Shield & Tables Assembly

F60+1 - 012 Cabinets & Covers Assembly

F60+1 - 013 Rear Slitter Assembly

F60+1 - 014 Separator Bar Assembly

ELECTRICAL SCHEMATICSF60+1 - 015 Falcon 60+ (-1) Wire Diagram

F60+1 - 016 Main Board Power Control Unit

F60+1 - 017 Main Board MCU Control Unit

F60+1 - 018 Main Board Sensor Interface Control Unit

F60+1 - 019 Display Board FND/ LED Control Unit

F60+1 - 020 Display Board Key Control Unit

F60+1 - 021 Pressure Detect Control Unit

REVISION SUMMARYDATE DWG # REV. REASON BY:

07/07/03 F60+1 - 002 A Heater connection wire part numbers added SNF

3

PROPRIETARYGBC 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 WITHOU T WRITTENPERMISSION FROM GBC. C

(3) 601410706Cross Bar

(2) 860014 Rewind Tube (Not Shown)

(1) 601410708Film Guide

(1) 604036229Guide Table

(3) 609070104Cross Fam Motor

(1) 601410695Sensor Cover

(1) 601410707Fan Cover

(2) 705200201Infrared Sensor Assembly

(1) 604036227Front Cover

(1) 601410726Top Heat Sensor Bar

(1) 604036231Wire Duct

(1) 601410727 (601410728)Sensor Bar Bracket, Left (Right)

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

UNLESS OTHERWISE SPECIFIEDTOLERANCE

DIM. ASSHOWN TOL. FINISH TO

BE 4151 Anderson Road, DeForest, WI 53532X/X X XX

XXX

+ 1/64

+ .050

+ .010

+ .020

125

ANGLES+ 1D

TITLE :

Bridge AssemblyGBC Falcon 60 + (-1)

DATE : DRAWN BY : DWG SCALE : DWG :

XXXX + .005 06/30/03 N/A N/A F60+1 - 001

RMP0178

Sticky Note

P/N#639900159 NEW STYLE CORE CHUCK ASS'Y 43MM. P/N# 634300081 NEW STYLE O-RING, REPLACING P/N# 634300057 O-RING.

pxlamant

Stamp

MANUFACTURE OR FOR ANY OTHER PURPOSE WITHOUT WRITTENCOPIED OR DISCLOSED IN WHOLE OR IN PART, OR USED FOR

FOR ENGINEERING INFORMATION ONLY AND SHALL NOT BE REPRODUCED,

GBC CLAIMS PROPRIETARY RIGHTS TO THEMATERIAL DISCLOSED ON THIS DRAWING. IT IS ISSUED IN CONFIDENCE

PERMISSION FROM GBC.

PROPRIETARY

C

4151 Anderson Road, DeForest, WI 53532

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


DIM. ASSHOWN

TOL.

+ 1/64

+ .050

+ .020

+ .010

+ .005

X/X

X

XX

XXX

XXXX

ANGLES+ 1D

FINISHTO BE

125TITLE :


RE

VIS

ION

CH

EC

KE

D B

Y :

Sea

n F

lood

Roller Housing AssemblyGBC Falcon 60 + (-1)

F60+1 - 005N/AN/A06/30/03

(1) 607040578Pull Roller, Upper

(1) 607040579Pull Roller, Driven

(2) 607040577Main Roller

(2) 613020738Pull Roller Block

(2) 613020740Pull Roller Spring Plate

(4) 701090208Pull Roller Spring

(4) 607040578Pull Roller Bushing

(2) 613020725Lock Collar

(4) 701109350Stripper Bolt

(2) 701010162Ball Bearing, UR205

(4) 613020703Bearing Spacer, Pull Roller

(2) 704150111Thermostat, 120 OC

(1) 601410700Thermostat Bracket

(2) 601410715Upper Heater Support

(2) 701010160Ball Bearing, UR210

(2) 613020719Heat Roller Bearing Block

(4) 613020702Bearing Block Guide

(1) 601410714Heater Support, Lower, Right

(1) 601410713Heater Support, Lower, Left

(2) 601410725Switch Plate Bracket

(1) 601410724Safety Switch Plate, Right

(1) 601410723Safety Switch Plate, Left

(2) 704090419Micro Sensor

(1) 601410722Safety Lock Plate, Right

(1) 601410721Safety Lock Plate, Left

(1) 601410719Roller Hole Cover

(2) 701020109Ball Bearing, ULCF210

(4) 613020704Bearing Spacer, Heat Roller

(1) 701080806Heat Roller Sprocket, 36T





PROPRIETARY

C




DIM. ASSHOWN

TOL.

+ 1/64

+ .050

+ .020

+ .010

+ .005

X/X

X

XX

XXX

XXXX

ANGLES+ 1D

FINISHTO BE

125TITLE :


RE

VIS

ION

CH

EC

KE

D B

Y :

Sea

n F

lood

Pull Roller Lift AssemblyGBC Falcon 60 + (-1)

F60+1 - 007N/AN/A06/30/03

(2) 701080808Lift Sprocker, Gear, 25T

(2) 701080809Lift Sprocket, Handle, 24T

(2) 613020737Lift Gear Shaft

(2) 613020736Lift Gear Block

(4) 701060150Oilless Bushing, SFB1615

(2) 701080814Idler Helical Gear

(2) 701080815Lift Helical Gear

(4) 701060152Oilless Bushing, SFB2015

(2) 613020735Lift Gear Block Cover

Right Assembly

Left Assembly

(2) 701080816Lift Screw





PROPRIETARY

C




DIM. ASSHOWN

TOL.

+ 1/64

+ .050

+ .020

+ .010

+ .005

X/X

X

XX

XXX

XXXX

ANGLES+ 1D

FINISHTO BE

125TITLE :


RE

VIS

ION

CH

EC

KE

D B

Y :

Sea

n F

lood

Unwind Brake AssemblyGBC Falcon 60 + (-1)

F60+1 - 009N/AN/A06/30/03

(2) 613020756Tension Wheel

(3) 613020760Unwind Clevis, Upper

(3) 613020755Tension Washer (3) 613020706

Brake Block, Upper

(6) 613020717Film Shaft Bushing

(3) 613020716Film Shaft Brake Block

(3) 613020705Brake Block, Lower

(3) 701110717Thrust Needle Roller Bearing Washer, AS5578

(2) 613020758Unwind Clevis, Lower, Lower Unwinds

(1) 613020759Unwind Clevis, Upper, Lower Unwinds

(1) 703070375Grill Knob

Upper Assembly

Lower Assembly

(3) 613020769Film Shaft

(3) 613020714Film Center Support

(6) 706111098Film Core Assembly

(3) 613020715Film Pipe Collar

pxlamant

Stamp





PROPRIETARY

C




DIM. ASSHOWN

TOL.

+ 1/64

+ .050

+ .020

+ .010

+ .005

X/X

X

XX

XXX

XXXX

ANGLES+ 1D

FINISHTO BE

125TITLE :


RE

VIS

ION

CH

EC

KE

D B

Y :

Sea

n F

lood

Wiring DiagramGBC Falcon 60 + (-1)

F60+1 - 015N/AN/A06/30/03

SSR SSR

1

2

113

5

4

7

6

8 9

10

12 13 14

15 16

25

20 21 22 23

24

26

27

29

18 19

28

37

38

39

17

ON

OFF

14

1-1

2-1

8

2-2

2-33-2 4

6 7 9-1

9-2 12-2

12-2

12-1

12-1

13

15

16-4

16-3

16-1

16-2

17

18

19

22-1

32-1

24

26-1 26-2 26-3

27

31 31

35 35

37-2

29-2

29-1

36

36

34

34

30-2

30-1

37-1

28-2

28-1

28-4

28-3

32-1

32-2

32-2

33-3

40

42

41

41

43 43

32

43

NC

CO

M

PO_3

PO_2

PO_1

SMS

SAF2

SAF1

EMS1

EMS2

EMS1

EMS2

SMS

FOOT

32

28

29

30

31

25

26

27

24

23

UPPER HEATER NOISE FILTER

COMPONENT NAMEPOWER CORD1

10

2

3

4

5

6

7

8

9

11

12

13

14

15

16

17

18

19

20

21

22

33

34

35

36

37

38

39

40

LOWER HEATER NOISE FILTER

UPPER HEATER THERMOSTAT

LOWER HEATER THERMOSTAT

UPPER HEATER

LOWER HEATER

UPPER SSR

LOWER SSR

FOOT SW

COOLING FAN1

COOLING FAN2

COOLING FAN3

PRESSURE SENSOR

UPPER INFRARED TEMP SENSOR

LOWER INFRARED TEMP SENSOR

SAFETY MICRO SW1

SAFETY MICRO SW2

FRONT EMERGENCY SW1

FRONT EMERGENCY SW2

REAR EMERGENCY SW1

REAR EMERGENCY SW2

ROLLER MOTOR

ROLLER MOTOR PHOTO INTERRUPTER

ROLLER MOTOR PROTECTION FUSE

ROLLER MOTOR DRIVER PCB

EMO PCB

MAIN PCB

TRANSFORMER PRIMARY FUSE

DISPLAY PCB

EMO PRIMARY PROTECTION FUSE

AC17V PROTECTION FUSE

TRANSFORMER

BRIDGE DIODE

CIRCUIT&FAN TERMINAL BLOCK

CIRCUIT NOISE FILTER

FOOT SW TERMINAL BLOCK

CIRCUIT BREAKER

EXTENSION TERMINAL BLOCK(UK16N)

REAR RUN,STOP MOMENTARY SW

41 SAFETY MICRO SW3

Rol_Mot

Pow

er

Sign

al

DC

4

Fuse

34

35

30

363-1

5

10

20

21

22-1

23

33-1

40

38

43

33

°C

BOTTOM TEMP.

°F

READY

°C

TOP TEMP.

°F

READY

3139





PROPRIETARY

C




DIM. ASSHOWN

TOL.

+ 1/64

+ .050

+ .020

+ .010

+ .005

X/X

X

XX

XXX

XXXX

ANGLES+ 1D

FINISHTO BE

125TITLE :


RE

VIS

ION

CH

EC

KE

D B

Y :

Sea

n F

lood

Main Board Power Control UnitGBC Falcon 60 + (-1)

F60+1 - 016N/AN/A06/30/03

DC1

VDD

+15VLAMP_POR

FAN_ON

+15VVDD

VSS

LAMP_PORVSS

LIVENUT

LIVENUT

EC

150

1000

0/63+

CN153

DC4

12

CN154

DC4

12

R15

0

4.7K

/2W

EC

152

10/5

0+

EC

153

10/5

0

+

EC

151

2200

/50

+

HS151

HS56x17U1517805

1 I

2G

3O

U1507815

1 I

2G

3O

CN158

AC18V

12

BD150

BD205

~~

+- 1

23

4

R101

100J

R103

1KJ

VDD

Q100

C10

2M

TRI100

BTA08

21

3

CC100 .1uF/250V

R102 100J

CN151

POWER

123

CN155

POWER

123

CN152

LAMP_POR

12

CN156

BD_DC

12

R100

330J

U100

MOC3043

1

2

4

6

CN150

AC_IN

12

CN160

REL_PRI

12

CN101

COOLING

12





PROPRIETARY

C




DIM. ASSHOWN

TOL.

+ 1/64

+ .050

+ .020

+ .010

+ .005

X/X

X

XX

XXX

XXXX

ANGLES+ 1D

FINISHTO BE

125TITLE :


RE

VIS

ION

CH

EC

KE

D B

Y :

Sea

n F

lood

Main Board MCU Control UnitGBC Falcon 60 + (-1)

F60+1 - 017N/AN/A06/30/03

SAFETY_INT

ADFB_LTEMPADFB_UTEMP

FOOT_SWSUB_PWR_SW

ENC_ROLRESET

USSRLSSR

SAFETY_MS

VDD+15V

VSSFAN_ON

U3

24LC04

1 A02 A23 A34 VSS 5SDA6SCL7WP8VDD R

12

4.7K

F

R13

4.7K

F

CC

4

22P

CC

5

22P

U2PIC17C756

1N

C2

VD

D3

AD

0/R

C0

4A

D15

/RD

75

AD

14/R

D6

6A

D13

/RD

57

AD

12/R

D4

8A

D11

/RD

39

AD

10/R

D2

10RD1/AD911RD0/AD812RE0/ALE13RE1/OE14RE2/WR15RE3/CAP416MCLR17TEST18NC19VSS20VDD21RF7/AN1122RF6/AN1023RF5/AN924RF4/AN825RF3/AN726RF2/AN6

27R

F1/

AN

528

RF

0/A

N4

29A

VD

D30

AV

SS

31R

G3/

AN

0/R

EF+

32R

G2/

AN

1/R

EF-

33R

G1/

AN

234

RG

0/A

N3

35N

C36

VS

S37

VD

D38

RG

4/C

AP

339

RG

5/P

WM

340

RG

7/T

X2/

CK

241

RG

6/R

X2/

DT

242

RA

5/T

X1

43R

A4/

RX

1

44 T0CKL/RA145 SCL/RA246 SDA/RA347 SCK/RB648 SDO/RB749 VDD50 CLKIN/OSC151 CLKOUT/OSC252 NC53 VSS54 PWM1/RB255 TCLK3/RB556 TCLK12/RB457 PWM2/RB358 CAP2/RB159 CAP1/RB060 INT/RA0

61A

D7/

RC

762

AD

6/R

C6

63A

D5/

RC

564

AD

4/R

C4

65A

D3/

RC

366

AD

2/R

C2

67A

D1/

RC

168

VS

S

CC

6

22P

CC

7

22P

X18MHz

CC

10

104J

U1/A

2904

3 +2 -

1

84

CC1 473J

Q1

C102M

BZ1

BU

ZZ

ER

+15V

R7

20KF

R11 1KF

VR2

5021

3

2VR3502

13

2

CN3

PRS_SEN

123

EC

1

0.47

/16

+

R5

1KF

R6

1KFR920KF

D1 1N751

CC3

473JR10 220F

CN4

ROL_SIG1 12 23 3

VDD VDD+15V +15V

R2200KF

R3200KF

R14

4.7K

F

VDD

SW

1

DIP

SW

11

2

VR1502

13

2

U1/B

2904

5 +6 -

7

84

CN6

DISPLAY_SIGNAL

1234567891011121314151617181920212223242526

CC

12

104J

EC

3

10/1

6

+

CC

13

104J

CC

14

104J

CC

15

104J

CC

16

104J

EC

2

10/1

6+

VDD

CC

8

104J

CN7

FOOT_ACL1 12 23 3

CN8

REL_SIG1 12 23 3

R1

4.7KF

CN1

ESW112

CN2

ESW212

R4

4.7KF

CC

2

104J

CC

25

103J

CC

17

103J

CC

18

103J

CC

19

103J

R8

3.3KF

EE_SDAEE_SCL

VDD

OSC1

EE_SCLEE_SDA

OSC2

MAIN_MOT_PWMVSS

VDD

SAFETY_INT

VSSVDD

RESETVSS

B_D

A40

94

VD

D

VS

S

BU

ZZ

ER

AD

FB

_UT

EM

PA

DF

B_L

TE

MP

VS

SV

DD

VD

DV

SS

OSC2OSC1

SAFETY_INT

BUZZER

ON/BRAKEMAIN_MOT_PWMVSS

T_DA4094T_CL4094T_ST4094

B_C

L409

4B

_ST

4094

P_D

A40

94P

_CL4

094

P_S

T40

94A

DF

B_S

PE

ED

ADFB_SPAREADFB_PRESSURE

ADFB_PRESSURE

SUB_PWR_SW

C/F_OPTION

ESW

ADFB_UTEMPADFB_LTEMP

C/F_OPTION

VDD

VSS

ADFB_SPARE

FOOT_SW

ENC_ROL

VDDVDD

VSS

T_DA4094T_CL4094T_ST4094B_DA4094B_CL4094B_ST4094ADFB_SPEEDP_DA4094P_CL4094P_ST4094

VSS

HOR_D1HOR_D2HOR_D3HOR_D4VER_D1VER_D2VER_D3VER_D4

VDD

HO

R_D

1

HO

R_D

2H

OR

_D3

HO

R_D

4V

ER

_D1

VE

R_D

2V

ER

_D3

VE

R_D

4

SUB_PWR_SW

RESETENC_ROLFOOT_SW

USSRLSSR

VDDVSS

+15VSAFETY_MS

ON

/BR

AK

E

FA

N_O

N

VSSVSS

VSS

SAFETY_MS

LSSRUSSR

VSSADFB_FOOT_ACCELVDD

ADFB_FOOT_ACCEL

RE

L_B

OA

RD

_SIG

REL_BOARD_SIG

VSS

ESW

VDD

VSS

FAN_ON

VER_D1VER_D2VER_D3VER_D4

'C/'F OPTION

(600~800J)





PROPRIETARY

C




DIM. ASSHOWN

TOL.

+ 1/64

+ .050

+ .020

+ .010

+ .005

X/X

X

XX

XXX

XXXX

ANGLES+ 1D

FINISHTO BE

125TITLE :


RE

VIS

ION

CH

EC

KE

D B

Y :

Sea

n F

lood

Main Board Sensor Interface Control UnitGBC Falcon 60 + (-1)

F60+1 - 018N/AN/A06/30/03

+15V

+15V

SUB_PWR_SWFOOT_SW

RESETUSSRLSSR

ENC_ROL

SAFETY_INTADFB_UTEMPADFB_LTEMP

SAFETY_MS+15VVSSVDD

R304.7KF

VDD

R32

470F

CC

24

104J

CN23

U_SEN

12345

R33

0J

CN27

L_SEN

12345

R38

0J

+15V

+15V

EC

20

10/1

6+

VDD

R37

4.7K

FD211N4148

R36

470RF

VDD

R25

56R

F

CC

21

101JR26

1KF

R21

470RF

U20/E

14584

11 10

CN20

SAFETY_INT

1234

VDD

R27

120R

F

CC

22

101JR28

3.3K

F

R24

470RF

U20/A

14584

1 2

CN22

ENC_ROL

1234

R29

4.7K

F

VDD

CC

23

104J

R31

4.7KF

CN26

USSR

12

Q20

C10

2M

R35

330RF

Q21

C10

2M

CN28

LSSR

12

R40

330RF

R23

4.7KF

R20

4.7K

F

VDD

CC20 104J

R22

470RF

U20/B

14584

34CN21

FOOT_SW

12

U20/C

14584

56U20/D

14584

9 8

U20/F

14584

13 12

R42

2.4K

F

R41

2.4K

F

R39

10K

F

CN25

CMS

12

CN24

SMS

12

D22 1N751

D20 1N751

R34

10K

F

SUB_PWR_SW

ADFB_UTEMP

ADFB_LTEMP

RESET

SUB_PWR_SWFOOT_SWENC_ROLRESETUSSRLSSR

SAFETY_MS

USSR

VDD

LSSR

VDD

FOOT_SWSAFETY_INT

SAFETY_INTADFB_UTEMPADFB_LTEMP

SAFETY_MS+15VVSSVDD

ENC_ROL

IR S

EN

SO

R T

PM

L1IR

SE

NS

OR

TP

ML1

ROLLER MOTOR ENCODER

SAFETY SENSOR

UPPER INFRARED SENSOR

LOWER INFRARED SENSOR

UPPER SSR

LOWER SSR

FOOT S/W

COVER MICRO SW

RESET CIRCUIT

SAFETY MICRO SW





PROPRIETARY

C




DIM. ASSHOWN

TOL.

+ 1/64

+ .050

+ .020

+ .010

+ .005

X/X

X

XX

XXX

XXXX

ANGLES+ 1D

FINISHTO BE

125TITLE :


RE

VIS

ION

CH

EC

KE

D B

Y :

Sea

n F

lood

Display Board FND & LED Control UnitGBC Falcon 60 + (-1)

F60+1 - 019N/AN/A06/30/03

VDD

T_DA4094T_CL4094T_ST4094

B_CL4094B_ST4094

B_DA4094

P_DA4094P_CL4094P_ST4094

ADFB_SPEED

VDDVSS

VDD

U1

MC14094

1 STR2 D3 CLK15 OE

4Q1 5Q2 6Q3 7Q4 14Q5 13Q6 12Q7 11Q89QS 10QS

U4

MC14094

1 STR2 D3 CLK15 OE

4Q1 5Q2 6Q3 7Q4 14Q5 13Q6 12Q7 11Q89QS 10QS

U6

MC14094

1 STR2 D3 CLK15 OE

4Q1 5Q2 6Q3 7Q4 14Q5 13Q6 12Q7 11Q89QS 10QS

U2

MC14094

1 STR2 D3 CLK15 OE

4Q1 5Q2 6Q3 7Q4 14Q5 13Q6 12Q7 11Q89QS 10QS

U5

MC14094

1 STR2 D3 CLK15 OE

4Q1 5Q2 6Q3 7Q4 14Q5 13Q6 12Q7 11Q89QS 10QS

U7

MC14094

1 STR2 D3 CLK15 OE

4Q1 5Q2 6Q3 7Q4 14Q5 13Q6 12Q7 11Q89QS 10QS

LD

4S

ND

-417

A

1G

2F

3C

M4

E5

D6

DP

7C

8C

M9

B10

A

LD

5S

ND

-417

A

1G

2F

3C

M4

E5

D6

DP

7C

8C

M9

B10

A

LD

6S

ND

-417

A

1G

2F

3C

M4

E5

D6

DP

7C

8C

M9

B10

A

U8

MC14094

1 STR2 D3 CLK15 OE

4Q1 5Q2 6Q3 7Q4 14Q5 13Q6 12Q7 11Q89QS 10QS

U9

MC14094

1 STR2 D3 CLK15 OE

4Q1 5Q2 6Q3 7Q4 14Q5 13Q6 12Q7 11Q89QS 10QS

U11

MC14094

1 STR2 D3 CLK15 OE

4Q1 5Q2 6Q3 7Q4 14Q5 13Q6 12Q7 11Q89QS 10QS

LD

1S

ND

-417

A

1G

2F

3C

M4

E5

D6

DP

7C

8C

M9

B10

A

LD

2S

ND

-417

A

1G

2F

3C

M4

E5

D6

DP

7C

8C

M9

B10

A

LD

3S

ND

-417

A

1G

2F

3C

M4

E5

D6

DP

7C

8C

M9

B10

ACC3102J

U3/B

4050

5 4 U3/C

4050

7 6

U3/A

4050

3 2R

3

10K

J

U12/B

4050

5 4 U12/C

4050

7 6

U12/A

4050

3 2

R19

10K

J

CC12102J

VDD

VR12KJ

13

2

R17

10K

J

CC10102J

VDD

CC11102J

R18

10K

J

VDD

R1

10K

J

CC1102J

R2

10K

J

CC2102J

LD

13L

D01

0

1K

12

K2

3K

34

K4

5K

56

K6

7K

78

K8

9K

910

K10

11A

1012

A9

13A

814

A7

15A

616

A5

17A

418

A3

19A

220

A1

LD

14L

D01

0

1K

12

K2

3K

34

K4

5K

56

K6

7K

78

K8

9K

910

K10

11A

1012

A9

13A

814

A7

15A

616

A5

17A

418

A3

19A

220

A1

VDD

CC6102J

R6

10K

J

U3/E

4050

11 12 U3/F

4050

14 15

U3/D

4050

9 10

LD7LED

LD8LED

LD9LED

LD10LED

LD11LED

LD12LED

R4

10K

J

CC5102J

CC4102J

R5

10K

J

VDDVDD VDD

LD

15

TO

P_L

D LD

16

BO

T_L

D

LD

17

FA

N_L

D

LD

18R

UN

_LD

LD

19S

TO

P_L

D

LD

20

FW

D_L

D

LD

21R

EV

_LD

U10

MC14094

1 STR2 D3 CLK15 OE

4Q1 5Q2 6Q3 7Q4 14Q5 13Q6 12Q7 11Q89QS 10QS

VDD

UK1UK2UK3UK4UK5UK6UK7UK8

UK9UK10LK1LK2LK3LK4LK5LK6

LK7LK8LK9LK10

TA1TB1TC1TD1TE1TF1TG1T_RDY_LD

TA2TB2

TD2TC2

TE2TF2TG2TOP_C_LD

TB3TC3TD3TE3TF3TG3

TA3

T_DA4094

VDD BA1BB1BC1BD1BE1BF1BG1B_RDY_LD

BA2BB2

BD2BC2

BE2BF2BG2BOT_C_LD

BB3BC3BD3BE3BF3BG3

BA3

BOT_F_LD

BG

1

VD

DB

E1

BD

1

BF1

BA

1

VD

DB

C1

BB

1

BA

2

VD

DB

C2

BB

2V

DD

BE

2B

D2

BF2

BG

2

VD

DB

E3

BD

3

BF3

BG

3B

A3

VD

DB

C3

BB

3

TA

1

VD

DT

C1

TB

1

TA

2

VD

DT

C2

TB

2

TA

3

VD

DT

C3

TB

3

TG

1

VD

DT

E1

TD

1

TF

1

VD

DT

E2

TD

2

TF

2T

G2

VD

DT

E3

TD

3

TF

3T

G3

T_CL4094T_ST4094

P_DA4094P_CL4094P_ST4094

ADFB_SPEED

TOP_F_LD

VDD

VSS

UK

2U

K3

UK

4U

K5

UK

6U

K7

UK

8U

K9

UK

10

LK

1L

K2

LK

3L

K4

LK

5L

K6

LK

7L

K8

LK

9L

K10

UK

1

T_DA4094T_CL4094T_ST4094B_DA4094B_CL4094B_ST4094ADFB_SPEEDP_DA4094P_CL4094P_ST4094VDDVSS

BDA4094BCL4094BST4094

BDA4094BCL4094BST4094

VDD VDD

B_DA4094B_CL4094B_ST4094

T_RDY_LD B_RDY_LD

TOP_C_LDTOP_F_LD

BOT_C_LDBOT_F_LD

LD_QS

LD_QS





PROPRIETARY

C




DIM. ASSHOWN

TOL.

+ 1/64

+ .050

+ .020

+ .010

+ .005

X/X

X

XX

XXX

XXXX

ANGLES+ 1D

FINISHTO BE

125TITLE :


RE

VIS

ION

CH

EC

KE

D B

Y :

Sea

n F

lood

Display Board Key Control UnitGBC Falcon 60 + (-1)

F60+1 - 020N/AN/A06/30/03

ADFB_SPEED

T_DA4094T_CL4094T_ST4094

B_CL4094B_ST4094

B_DA4094

P_DA4094P_CL4094P_ST4094

VDDVSS

L_DA4094L_CL4094L_ST4094

VDD

CC

5610

4J

CC

5410

4J

CC

5310

4J

CC

5210

4J

CC

5110

4J

CC

5010

4J

CC

5510

4J

CC

5710

4J

CC

5910

4J

CC

5810

4J

SW

60

TO

P_M

EA

S12

SW

61

T_T

EM

P_U

P12

SW

63

BO

T_M

EA

S12

SW

62

T_T

EM

P_D

N12

SW

64

B_T

EM

P_U

P12

SW

65

B_T

EM

P_D

N12

SW

50

TH

SW

_ON13

24

SW

51

TH

SW

_OFF13

24

SW

52

BH

SW

_ON13

24

SW

53

BH

SW

_OF

F13

24

SW

54

FA

N_S

W_O

N13

24

SW

55

FA

N_S

W_O

FF13

24

SW

56

FW

D_S

W

13

24

SW

57

RE

V_S

W

13

24

SW

58

RU

N_S

W

13

24

SW

59

ST

OP

_SW

13

24

CN51

DISPLAY_SIGNAL

1234567891011121314151617181920212223242526

R53

470J

R52

470J

R50

470J

CN50

REAR_SW

112233

R51

470J

R54 4.7KJ R55 4.7KJ R56 4.7KJ R57 4.7KJE

C50

10/1

6

+

CC

6010

4J

CC

6110

4J

CC

6210

4J

VDDVDD

HOR_D1

HOR_D2

HOR_D3

HOR_D4

VER_D1

VER_D2

VER_D3

VER_D4VSS


VSS

HOR_D1HOR_D2HOR_D3HOR_D4VER_D1VER_D2VER_D3VER_D4

VDD


RSW_STOPRSW_RUN

RSW_STOPRSW_RUNHOR_D3

L_DA4094L_CL4094L_ST4094

VDDVSS

VSSVSS

VSS





PROPRIETARY

C




DIM. ASSHOWN

TOL.

+ 1/64

+ .050

+ .020

+ .010

+ .005

X/X

X

XX

XXX

XXXX

ANGLES+ 1D

FINISHTO BE

125TITLE :


RE

VIS

ION

CH

EC

KE

D B

Y :

Sea

n F

lood

Pressure Detect Control UnitGBC Falcon 60 + (-1)

F60+1 - 021N/AN/A06/30/03

CN1

PRS_SEN

123

SV110KJ

1

2

3

456 7

TECHNICAL SERVICE & SUPPORT BULLETIN 500 Bond St.

Lincolnshire, IL. 60069

T.S.S.B. NO. 1003 DATE: 8/12/04

MODEL: FALCON 60+(-1)

SUBJECT: NIP PRESSURE & SCALE BAR (FORCE GAUGE CALIBRATION) PAGE: 1 OF 7

Steps to calibrate nip pressure and scale bar on the GMP version of the Falcon 60+(-1).

1) Make sure main rollers nip has been set correctly, otherwise, adjust the lift rod on either side of the machine (approx. 5/8” dia. X 18” long), by threading in or out through the lower clevis. To thread in, the jam nut above the clevis needs to be loosened first, and tightened after the adjustment has been made. See Fig. 1

2) Open main rollers, then bring the upper main roller down until it touches the center of the bottom roller (crown effect). Apply gradual pressure until gaps at both ends of the rollers are closed. Stop lowering the upper roller as soon as the ends of the upper and lower rollers are making contact.

3) At this stage, make sure springs on both sides of the machine spin freely with no up and down movement. As necessary, loosen lock collar to adjust height along the lifting rod by threading up or down to establish a distance of 1 3/16” or approx. 30mm from the lower surface of the hinge block to the top surface of the lock collar. See Fig. 2 Make sure the distance required are established on both side of the machine.

Note: Once the distance has been established, there will still be enough space for the springs to move freely. This is required in order to have a quick initial response from the pressure scale bar. Also, this will help to achieve flat nip across the full working width (62”) at higher-pressure settings (such as 65% to 70% on the force gauge). This will provide a flat nip, even with lesser pressure settings for narrower materials and substrates then 62”. In addition, this will prevent foam board from being crushed when desirable light pressure is applied.

4) Use crank handle to close main rolls nip until strip bolt head is lifted up from the roll lift block to a height of 3/8”. This will be measured from the bottom side of the bolt head to the top surface of the roll lift block. Make sure strip bolt head are tight. See Fig. 3 Make sure the distance required are established on both side of the machine.

5) Make sure that the pressure lever is roughly in the center of the linier potentiometer (pressure sensor). If not, then adjust the lever by loosening the socket head bolts, reposition and tighten the bolts. This will mean that the black pressure sensor switch will be in the center as well. Tighten the two socket head bolts firmly to prevent the lever rod from tilting from its position in relation to the lift rod. See Fig. 4 Note: Having pressure lever within the middle will help to increase voltage magnification, which will be needed for later steps.

6) Raise Nip Rollers until there gapped, and then lower Nip Rollers until Rollers just touch. NOTE: To change force gauge pressure scale display from a single indicator light to a full indicator light bar, hold down Fan Off button. To revert back to a single indicator light, hold down Fan Off button.

7) Use the crank handle to apply slight downward pressure (1 ½ -3/4 turns) until the 5% bar lights up on the force gauge. See Fig. 5

8) If the force gauge shows more than 5%, then rotate the Minima trim pot clockwise until only the 5% LED bar is lit. If no LED bar is illuminated on the force gauge, then rotate the Minima trim pot counter-clockwise until the 5% LED becomes illuminated. Fig. 7 shows locations of both the “Minima” and “Maxima” trim pots on the motherboard.

NOTE: Turning trim pots clockwise or counter clockwise may depend how trim pots are installed on P.C. Board. If mounted upside down, clockwise would then be counter clockwise and counter clockwise would be clockwise.

9) The force gauge should be at 100% after rotating the crank handle 4 turns. If the force gauge does not reach 100% after the fourth turn or if it reaches 100% before the fourth turn is complete then some fine-tuning and adjustments need to be made. These are described in the following section.

A) Bring pressure down to the first bar (5%). B) Apply pressure again by making one complete turn of the crank

handle. After one complete turn the force gauge should be at 35%. If the force gauge states more then 35% (40% or higher), then turn the “Maxima” trim pot clockwise until the force gauge is at 35%. On the other hand, if the force gauge is at less than 35% then turn the “Maxima” trim pot counter clockwise until 35% is attained on the force gauge.

C) Rotate the crank handle 3 complete turns; the force gauge should state 100%. If not, then adjust the pressure lever up a little (very slight); force gauge should now state 100%. Adjusting the pressure lever will upset the calibration done in step B; repeat step B until step C is not required. See Fig. 6

The force gauge calibration should be complete at this

point. NOTE: Turning trim pots clockwise or counter clockwise may depend how trim pots are installed on P.C. Board. If mounted upside down, clockwise would then be counter clockwise and counter clockwise would be clockwise.



T.S.S.B. NO. 1003A DATE: 4/27/04

MODEL: FALCON 60+(-1)

SUBJECT: UPGRADED HEATER & CIRCUIT BREAKER KIT PAGE: 1 OF 4

The upgraded higher wattage (3250 Watts, 13.5 Ω) Heater Kits for the Falcon 60+(-1) can be ordered under part number 005172. The Heater Kit contains 2 heaters and new heater wires to do one machine. Individual high wattage heaters can also be ordered under part number 638200369. These heaters will heat up much faster than the original heaters. If your customer would like to have the higher wattage Heater Kit installed, they must change their 30-amp service to a 40-amp service. With this enhancement, you must install the upgraded Circuit Breaker Kit to accommodate the higher wattage heaters and the 40-amp service. The Circuit Breaker Kit can be ordered under part number 005156. The individual Circuit Breaker can also be ordered under part number 637400019. The original heaters, part number 706025090 for the Falcon 60+(-1) (2750 Watts, 16.0 Ω) are still available for customers who choose not to install the upgraded higher wattage Heater Kit. Listed below are the bill of materials (BOM) for the Heater Kit and Circuit Breaker Kit. The following pages are the installation instructions for the Circuit Breaker Kit.

Higher Wattage Heater Kit (BOM) P/N# 005172 PART NO. DESCRIPTION QTY 638200369 Quartz Heater 3250W 13.5 Ω 2 638001097 Heater Wire Assembly 2 638001697 Heater Wire Assembly 2

Circuit Breaker Kit (BOM) P/N# 005156 PART NO. DESCRIPTION QTY 637400019 Circuit Breaker 1 637600076 Terminal Block 2

270075 Red 10AWG. 10” Wires 2 215021 Ring Terminal 1/4” 12-10AWG 2 820187 Installation Instructions 1

820-187 by: FW REV. A – 3-25-04

PAGE 1 OF 3

CIRCUIT BREAKER KIT INSTRUCTIONS FOR F60+,-1 3250W HEATERS

1. Remove end cabinet covers on control side of machine.

2. Disconnect plug from the receptacle, retain the plug under your control for your safety.

3. Remove the original CIRCUIT BREAKER. Transfer the line terminal wires (from the

original Circuit Breaker) to the line terminals of the new circuit breaker. Temporarily leave the original circuit breaker connected to the terminal block. Remove the original wires that run from the original circuit breaker to the terminal block. Make note of which terminal blocks the wires are connected to, as these are the terminal blocks that will be replaced.

4. Attach the two new load wires (10AWG included in the kit) to the new Circuit Breaker

and mount/install the new circuit breaker.

5. Connect the two loose 10AWG load wire ends (from the new C.B.) to each of the two new terminal block sections (one for each leg of power).

6. Transfer the wires from the original terminal block sections (there are two original

terminal block sections jumpered together for each leg) to one of the new terminal block sections connected to the new circuit breaker. (Fig. 1,2,3 &4)

7. Remove the original terminal block sections from the DIN rail (this will also remove the

original circuit breaker) and snap the new terminal block sections onto the DIN rail.

8. Change AMP rating to read 40A on the serial number sticker. Make sure touse permanent ink.

9. Double check all wires for accuracy and be sure each wire is securely tightened.

10. Test machine and reinstall end panels.

820-187 by: FW REV. A – 3-25-04

PAGE 2 OF 3

FIGURE 1

FIGURE 2

820-187 by: FW REV. A – 3-25-04

PAGE 3 OF 3

FIGURE 3

FIGURE 4



T.S.S.B. NO. 1003B DATE: 8/9/04

MODEL: FALCON 60+ (-1)

SUBJECT: MAXIMUM TEMPERATURE CALIBRATION PAGE: 1 OF 2

FALCON60+(-1) MAXIMUM TEMPERATURE CALIBRATION

1. The temperature controllers are capable of being set to 320°F, but it is not recommended per GBC specifications. GBC’S specifications for Maximum Temperature for the Top and Bottom Heaters for the Falcon 60+(-1) must be set at 270°F.

2. Turn power switch on. Press and hold the “MOTOR STOP KEY” on the Control Panel for three seconds or until a beep has sounded. NOTE: On some Falcon 60+(-1) the E-STOP must be pressed in before calibration procedure can be started.

3. After the beep has sounded, you must press the following keys very quickly or you will not get into the Calibration Mode .

4. “PRESS TOP HEATER OFF KEY” 5. “PRESS BOTTOM HEATER ON KEY” 6. “PRESS TOP HEATER ON KEY” 7. “PRESS BOTTOM HEATER OFF KEY”

TOP HEATER OFF KEY

TOP HEATER ON KEY

BOTTOM HEATER ON KEY

BOTTOM HEATER OFF KEY

MOTOR STOP KEY

Page: 2 OF 2

MAXIMUM TEMPERATURE CALIBRATION CONTINUED

8. To adjust the top temperature, “PRESS TOP TEMP UP or DOWN ARROW KEY” to achieve 270°F.

9. To adjust the bottom temperature, “PRESS BOTTOM TEMP UP or DOWN ARROW KEY” to achieve 270°F.

10. Once 270°F has been set, press and hold the “MOTOR STOP KEY” until the beep has sounded.

11. The Maximum Temperature Calibration procedure is now complete.



T.S.S.B. NO. 1003C DATE: 10/15/04


SUBJECT: KIT, UNDWIND SPRING/MID TABLE PAGE: 1 OF 1

Some early versions of the Falcon 60+ (-1), you may have machines that are experiencing all or no upper and lower brake tension, and the middle guide table bowing upward in the middle of the machine. To improve brake tension control, a kit has been created that will include installation instructions, wavy washers, new internal brake block to accommodate the wavy washers, and other necessary parts. The solution to prevent the middle guide table from bowing upward is to secure the table in the middle by drilling, tapping, and inserting a setscrew. The kit will include instructions, drill bit, tap, setscrew, and tap handle. The techs can keep the tap handle for future use. What happens is the middle guide table heats up and the metal expands, and the only room for expansion to take place is in the middle of the table. This kit is now available to address both of these issues, and should be implemented at the same time. The kit can be ordered under part number 005176. Please update your Parts Manual with this information.



T.S.S.B. NO. 1003D DATE: 12/14/04

MODEL: F60+ -1

SUBJECT: Solving Heater Error PAGE: 1 of 1

Some F60+-1’s suffer from a heater error that occurs from time to time. This will become irritating and annoying as the error will have to be cleared before operation can be continued. The fix is to ground the upper heat sensor bar. Begin by measuring the resistance from the heat sensor bar to the frame of the machine. Proceed with the grounding instructions listed below if the resistance is more than zero. The heat sensor bar is secured by two bolts on each side of the machine. Remove the paint from the bar where it meets the frame of the machine with a file. Repeat the filing process until the resistance between the heat sensor bar and the frame equals zero. R.G.M 12/14/04

TECHNICAL SERVICE & SUPPORT BULLETIN T.S.S.B. NO. 1003E DATE: 8/19/05


SUBJECT: MOTORS W/INCORRECT GEAR BOX’S & P/N#’S FOR ASSEMBLIES PAGE: 1 Of 1

We were sent DC Main Motors that were correct for the Falcon 60+ (-1), but the attached Gearboxes were incorrect. The Main Motor with Gearbox attached is part number 609060112. When a technician replaces an old Motor with a new Motor, the gear ratio may be way off, causing the machine to run over thirty feet per minute, resulting in damaged boards. If you have machines running too fast and blowing boards, this may be the problem and should be corrected. To identify the correct Gearbox, the ID number is S9KC120BH-S. The incorrect Gearbox ID number is S9KC20BH-S. If you need to replace a bad Motor and the Gearbox is not damaged, you can change Gearboxes. Remove the Gearbox that has the correct ID number (S9KC120BH-S) from the bad motor. Remove the incorrect Gearbox (S9KC20BH-S) from the new Motor and discard. Replace the Gearbox with correct ID number from the bad Motor on the new Motor. If your Motor and Gearbox are both bad, replace with Motor/Gearbox that has correct ID number. Do not return Motors with incorrect Gearboxes, dispose of them. Part number 701010160 for the F60+ (-1) Chill Bar Bearings is incorrect in the Operator/Parts Manual. The correct part number is 635400119. Listed below are new part numbers for Assemblies for the Falcon 60+ (-1).

• Safety Shield Cover Assembly P/N# 639900142 • Clutch Assembly P/N# 639900143. • Control Panel Assembly P/N# 639900144

Please update your F60+ (-1) Operator/Parts Manual, P/N# 1722885 with the correct part numbers for the Chill Bar Bearings and the new Assemblies. R.P. 8/19/05

TECHNICAL SERVICE & SUPPORT BULLETIN T.S.S.B. NO. 1003F DATE: 8/24/05

MODEL: FALCON 60+ -1

SUBJECT: ELECTRONIC UPGRADE KIT 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

1. Remove electrical side cover and electrical protective cover.

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

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

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

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

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

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

8. 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.

9. 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.

10. 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”

11. 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.

12. 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.

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

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

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

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

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

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

19. 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-

20. 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.

21. 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.

22. 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.

23. 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.

24. 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.

25. 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.

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

How To Retrofit F60+KIT # 005-177

Main RelayBoard

To_Motor

TO PLUG ON MAIN MOTOR

MAIN BOARD

ROL_SIG

CN5

ResistorOMRONRELAY

5 1

8 4 14 12

13 9

PHEONIXCONTACT

RELAY

14

12

11

11

A1

B

A2

A2

Motor DriveBoard

FUSE

DC

SIGNAL

POWER

MOTOR

Motor

24V DCPower Supply

L

N

+ -V V

POWER

48V DCPower Supply

L

N

+ -V V

+

-

To OriginalLamp Male Plug

To Main BoardLAMP_POR

(RED) (WHT) (GRN)

TO GROUND

TO GROUND

RED WIRE

GREEN WIRE

3 W

IRE

SHIE

LDE

DC

ABL

E

3 W

IRE

SH

IELD

ED

CAB

LE

RED WIRE

GREEN WIRE

RED

WIR

E

BLAC

K W

IRE

RED

WIR

E

BLA

CK

WIR

E

TO F

USE

RED WIRE

BLACK WIRE

RED WIRE

BLACK WIRE

EXPLODED VIEW

BLACK WIRE

RED WIRE

RED WIRE

BLACK WIRE

YELLOW WIRE

YELLOW WIRE

RED WIRE

RED WIRE

BLA

CK

WIR

E

RED

WIR

E

FEMALE PLUG

BR

OW

N W

IRE

BLU

E W

IRE

BLACK WIRE

To AC MainTerminal Block. BLACK WIRE

MALE PLUG

MALE PLUG FEMALE PLUG

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

AC Supply-

• 19 Inch Brown 22 Gauge #6 Fork • 19 Inch Blue 22 Gauge #6 Fork • 5 Inch Brown #8 Fork • 5 Inch Blue #8 Fork

Lamp-

• 30.5 Inch Red 22 Gauge 250 Female • 30.5 Inch Black 22 Gauge 250 Female • 6 Inch Red 22 Gauge 250 Male • 6 Inch Black 22 Gauge 250 Male • 28 Inch Red 22 Gauge #6 Fork • 28 Inch Black 22 Gauge #6 Fork • 8 Inch Red 22 Gauge #6 Farro • 8 Inch Black 22 Gauge #6 Farro

48VDC-

• 23 Inch Red 22 Gauge #6 Fork • 23 Inch Black 22 Gauge #6 Fork

Relay Jumper-

• 8 Inch Red 22 Gauge #6 Fork-#6 Farro CN5 Motor-

• 10 Inch Red 14 Gauge #6 Fork-250 Male • 10 Inch Black 14 Gauge #6 Fork-250 Male

Motor-

• 16 Inch Red 14 Gauge #6 Fork-250 Female • 16 Inch Black 14 Gauge #6 Fork-250 Female

Grounds-

• 23 Inch 14 Gauge Green/Yellow #10 Ring X 2 • 23 Inch 14 Gauge Green/Yellow #10 Ring X 2

Resistor-

• 9 Inch Yellow 22 Gauge #6 Fork • 9 Inch Yellow 22 Gauge #6 Fork

Signal Wire-

• 3C, Red, Green, White.24 Inch. Signal connector

TECHNICAL SERVICE & SUPPORT BULLETINT.S.S.B. NO. 1000I DATE: 10/12/05

MODEL: VARIOUS MODELS

SUBJECT: HEATER WIRES WITHOUT BRASSCONNECTORS

PAGE: 1 Of 1

Here is a list of part numbers for heater wires without brass connectors for various laminators. Thebrass connectors are separate from the heater wires. When ordering heater wires you will need toorder 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 connectorsunder part number 637500017. The brass connectors can be crimped on theheater wires by using a standard wire crimping tool. The heater wire and brassconnector 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

http://www.gbc.com

Documents

FALCON 60+ (-1) Parts List_1_PARTS.pdfILLUSTRATED PARTS F60+1 - 001 Bridge Assembly F60+1 - 002 Roller & Heaters Assembly F60+1 - 003 Idlers & Unwinds Assembly F60+1 - 004 Drive Assembly