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
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.
UNLESS OTHERWISE SPECIFIEDTOLERANCE
DIM. ASSHOWN
TOL.
+ 1/64
+ .050
+ .020
+ .010
+ .005
X/X
X
XX
XXX
XXXX
ANGLES+ 1D
FINISHTO BE
125TITLE :
DATE : DRAWN BY : DWG SCALE : DWG :
RE
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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
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.
UNLESS OTHERWISE SPECIFIEDTOLERANCE
DIM. ASSHOWN
TOL.
+ 1/64
+ .050
+ .020
+ .010
+ .005
X/X
X
XX
XXX
XXXX
ANGLES+ 1D
FINISHTO BE
125TITLE :
DATE : DRAWN BY : DWG SCALE : DWG :
RE
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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
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.
UNLESS OTHERWISE SPECIFIEDTOLERANCE
DIM. ASSHOWN
TOL.
+ 1/64
+ .050
+ .020
+ .010
+ .005
X/X
X
XX
XXX
XXXX
ANGLES+ 1D
FINISHTO BE
125TITLE :
DATE : DRAWN BY : DWG SCALE : DWG :
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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
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.
UNLESS OTHERWISE SPECIFIEDTOLERANCE
DIM. ASSHOWN
TOL.
+ 1/64
+ .050
+ .020
+ .010
+ .005
X/X
X
XX
XXX
XXXX
ANGLES+ 1D
FINISHTO BE
125TITLE :
DATE : DRAWN BY : DWG SCALE : DWG :
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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
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.
UNLESS OTHERWISE SPECIFIEDTOLERANCE
DIM. ASSHOWN
TOL.
+ 1/64
+ .050
+ .020
+ .010
+ .005
X/X
X
XX
XXX
XXXX
ANGLES+ 1D
FINISHTO BE
125TITLE :
DATE : DRAWN BY : DWG SCALE : DWG :
RE
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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
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.
UNLESS OTHERWISE SPECIFIEDTOLERANCE
DIM. ASSHOWN
TOL.
+ 1/64
+ .050
+ .020
+ .010
+ .005
X/X
X
XX
XXX
XXXX
ANGLES+ 1D
FINISHTO BE
125TITLE :
DATE : DRAWN BY : DWG SCALE : DWG :
RE
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CH
EC
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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/
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0/R
EF+
32R
G2/
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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
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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
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EM
PA
DF
B_L
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MP
VS
SV
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VD
DV
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OSC2OSC1
SAFETY_INT
BUZZER
ON/BRAKEMAIN_MOT_PWMVSS
T_DA4094T_CL4094T_ST4094
B_C
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4B
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P_D
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P_S
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DF
B_S
PE
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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
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HO
R_D
4V
ER
_D1
VE
R_D
2V
ER
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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)
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.
UNLESS OTHERWISE SPECIFIEDTOLERANCE
DIM. ASSHOWN
TOL.
+ 1/64
+ .050
+ .020
+ .010
+ .005
X/X
X
XX
XXX
XXXX
ANGLES+ 1D
FINISHTO BE
125TITLE :
DATE : DRAWN BY : DWG SCALE : DWG :
RE
VIS
ION
CH
EC
KE
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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
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.
UNLESS OTHERWISE SPECIFIEDTOLERANCE
DIM. ASSHOWN
TOL.
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+ .020
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FINISHTO BE
125TITLE :
DATE : DRAWN BY : DWG SCALE : DWG :
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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
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.
UNLESS OTHERWISE SPECIFIEDTOLERANCE
DIM. ASSHOWN
TOL.
+ 1/64
+ .050
+ .020
+ .010
+ .005
X/X
X
XX
XXX
XXXX
ANGLES+ 1D
FINISHTO BE
125TITLE :
DATE : DRAWN BY : DWG SCALE : DWG :
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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
T_DA4094T_CL4094T_ST4094B_DA4094B_CL4094B_ST4094ADFB_SPEEDP_DA4094P_CL4094P_ST4094
VSS
HOR_D1HOR_D2HOR_D3HOR_D4VER_D1VER_D2VER_D3VER_D4
VDD
T_DA4094T_CL4094T_ST4094B_DA4094B_CL4094B_ST4094ADFB_SPEEDP_DA4094P_CL4094P_ST4094
RSW_STOPRSW_RUN
RSW_STOPRSW_RUNHOR_D3
L_DA4094L_CL4094L_ST4094
VDDVSS
VSSVSS
VSS
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.
UNLESS OTHERWISE SPECIFIEDTOLERANCE
DIM. ASSHOWN
TOL.
+ 1/64
+ .050
+ .020
+ .010
+ .005
X/X
X
XX
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ANGLES+ 1D
FINISHTO BE
125TITLE :
DATE : DRAWN BY : DWG SCALE : DWG :
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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.
TECHNICAL SERVICE & SUPPORT BULLETIN 500 Bond St.
Lincolnshire, IL. 60069
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
TECHNICAL SERVICE & SUPPORT BULLETIN 500 Bond St.
Lincolnshire, IL. 60069
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.
TECHNICAL SERVICE & SUPPORT BULLETIN 500 Bond St.
Lincolnshire, IL. 60069
T.S.S.B. NO. 1003C DATE: 10/15/04
MODEL: FALCON 60+ (-1)
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.
TECHNICAL SERVICE & SUPPORT BULLETIN 500 Bond St.
Lincolnshire, IL. 60069
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
MODEL: FALCON 60+ (-1)
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