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GBC ORCA-IV User's Manual

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1. Characteristic Specifications Dimensions 86 x 48 x 73 Lx Dx H 2 2 x 1 2 x 1 7 m Weight Uncrated 3060 Ibs 1814 kg Main Rolls 62 157 cm roll face with high release silicon rubber coating for 54 wide materials Main Roll Open 1 25 3 2 cm maximum open ing ing Material Uses transfer materials 0 54 0 137 2 cm wide Handles materials on 3 7 6 cm ID cores with material diameters up to 15 38 1 cm Speeds 0 to 10 fpm 0 to 3 1 mpm for transfer process with variable speed and 19 fpm 5 8 mpm reversible action start and stop controlled by the instrument panel Safety Features e All electrical and moving mechanical parts are located in bolted cabinets Emergency stop buttons with a reset button circuit e Fully guarded with inter locks e Emergency stop kick cables Options e Preheater module Installation 230VAC 50 or 60 Hz three Requirement phase 45A per phase with pre heater 35A per phase without preheater for 4 wire delta hookup 40A service without the preheater and 50A service with the preheater is required Filtered air at 1 5 cubic feet per minute cfm 50 liters minute at a pressure of 100 pounds per square inch psi 700 kPa Specifications GBC Pro Tech 1998 October Specifications ORCA IV Image Transfer Laminator Operation Manual Blank page 6 2 GBC Pro Tech 1998 October ORCA IV Image Transfer Laminator Oper
2. The film must be centered on the unwind for best performance This is vital when two films are fed together If the two films are not aligned feed problems wrinkles and other assorted troubles will occur See Table 3 2 for centering and alignment information A IMPORTANT Carefully align the two films being fed into the nip If not you will obtain poor results Operation Heating Use the following instructions when heating the upper main roll 1 Set the heater switch to ON 2 Adjust the temperature controller for the desired operating temperature using the temperature con troller set point adjustment To adjust the set point hold the star button down and press the up or down arrow on the temperature controller 3 Allow the roll to come to temperature After the roll has come up to set temperature let the rolls run together for 5 minutes to produce even heat or you can also simply start the process a little slower and bring it up to speed as the roll reaches prime oper ating temperature 4 The temperature controller has an LED light emit ting diode readouts to indicate the status of the heating system 5 It will take approximately 45 minutes for the upper main roll to reach operating temperature When the preset operating temperature has been reached the machine is ready to use GBC Pro Tech 1998 October 3 11 Operation Recommended Materials Films Excluding Vinyl Transfer and
3. Overlamination The ORCA IV image transfer laminator is capable of processing a wide range of pressure sensitive and ther mal laminates onto an equally wide range of image materials The primary considerations are e Laminate adhesives are compatible with image materials e The materials properly activate below the maxi mum roll temperature and within the speed and roll nip pressure ranges available on the laminator It is the operator s responsibility to ensure the compati bility and operational settings for any laminates image material combination GBC Pro Tech Technical Sup port is available at the number provided in the Mainte nance chapter for advice on some material combinations Vinyl Transfer and Overlamination Mate rials This machine is designed to do transfer using complete systems provided by companies such as GBC Pro Tech 3M or Rexam This system includes the paper inks vinyl and overlaminate films specifically matched to offer excellent performance Some vinyl materials offered by other companies will emit chemicals that will cause permanent damage to the rolls A IMPORTANT Substituting materials can cause severe damage to your machine and is not recommended or covered under our warranty It is the operator s responsibility to ensure compatibil ity and operational settings for the transfer process Consult your transfer system supplier to ensure the cor rect combinations of materials
4. machine properly Press the machine reset above main switch See Machine Reset Procedure on page 3 3 Verify that the kick cable is truly resetting listen look Adjust the kick cable See Adjusting the Kick Cable on page 3 3 d Press the machine reset above main switch See Machine Reset Procedure on page 3 3 e Remove fuses and replace if nec essary Be sure to replace with the correct size fuses two 6A fuses for the motor and one 1A fuse for the power supply 13 I pressed the motor reverse a see problem 12 a See problem 12 button but the rolls would not turn 14 I pressed the main roll down a Is there air pressure to the a Verify that the air supply is suffi push button but the roll did machine cient S100 psi not go down b Is there at least 20 psi on the b Turn up regulator for main roll gauge pressure c Are the e stop push buttons c See problem 12 pressed and the kick cables reset d See problem 12 d Is the machine reset e Reset the machine See Machine Reset Procedure on page 3 3 15 I pressed the main roll up a Is there air pressure to the a Verify that the air supply is suffi push button but the rolls did machine cient S100 psi not go up b Is the machine reset b Reset the machine See Machine Reset Procedure on page 3 3 16 I pressed the pull roll down Is there air pressure to the a Verify that the air supply is suffi push button but the rolls did machine c
5. operation H Manual mode with the preheater off P Automatic mode with the preheater on L Manual mode with the preheater on No letter Automatic mode with the preheater off The following codes alert you to machine status 0 The machine is reset and ready to be started 8888 Main power has just been turned on and the main reset has not yet been pressed In addition to these codes if an emergency stop button or kick cable is activated the decimal point will no longer be displayed for example 3 0 would change to 3 0 Simply resetting the emergency stop button or kick cable does not change the display You must also press the main machine reset button for display to read 0 indicating the machine is ready to be started Note that you must reset the emergency stop button or kick cable before press ing the main machine reset or the machine will not be reset SPEED ADJUSTMENT Adjusts the speed of the machine from zero to maximum as the control is turned clockwise Turn control knob slowly for best results PULL ROLL TORQUE ON OFF Allows you to turn the pull roll clutch torque pressure on or off without changing the pressure settings PULL ROLL PULL FORCE DISPLAY Dis plays the air pressure of the clutch torque or pull force PULL ROLL UP DOWN Sets the pull roll to the up load or down operate position PULL ROLL TORQUE CONTROL Varies the air pressure fed to the clutch that drives the lower
6. sion Adjust cylinder flow controls Measure from the side frame to the edge of material in front and back to verify that the material is webbed through straight Try a different roll Raise and lower the roll pop up and down to pull the initial loose web straight and tight Call Technical Support to disas semble and lubricate the cylinder lift linkage qualified service technician required GBC Pro Tech 1998 October 4 7 Maintenance and Troubleshooting ORCA IV Image Transfer Laminator Operation Manual A Problem Possible Cause Corrective Action Number 7 Rewound material not even a Was the initial material webbing a Measure carefully from sideframe on edge straight and straighten webbing b Is the roll telescoped b Use end plates on all unwinds c Is there excessive tension c Lower the tension d Is ita poor roll of film soft end d Try a new roll 8 Plastic slitter tube has devel Has the slitter idler increased in a Sand and or file down the higher oped a larger diameter where diameter at the point of contact spots in the plastic tube the round knives cut causing with the blades b Replace the slitter tube note use paper stress lines and paper as little pressure on the slitter as isanne at peal idle possible to increase the life of the slitter tube 9 Rewind is not turning a Is the rewind engaged in the a Line up the drive tang and side drive sh
7. y to do this will reduce the life of your rolls and may cause perma nent damage 30 The alarm does not come on a Is there a technical problem with Contact Technical Support for the conditions outlined the alarm above 31 When the rolls are stopped I a Are the e stop push buttons See problem 12 pressed the switch to adjust pressed and the kick cables reset Reset the machine See Machine the pressure to the brakes or b Is the machine reset Reset Procedure on page 3 3 clutches and nothing hap pened 32 When the rolls are moving I This may be normal When the Push and release button do not pressed the switches to machine is running the computer hold Try manual mode adjust the pressure to the takes over the settings and adjusts obest II the pressure to the brakes and In automatic mode with the motor noh clutches The change that you off set the web force When it ad id e A attempted to make may have been starts to run see calculated pres too small to see on the gauge as a sure sent to brake for that percent allowable pressure for required web force Even though that size roll you do not see a large increase in the pressure on the display feel the web tension manually to see 1f the brake tension has changed 33 I pressed the motor forward 4 Are the shafts locked in Close the doors and lock in the push button and the arrow shafts then try the motor light did not come on GBC Pro Tech 1998 Octobe
8. 3 1 Safety labels 1 5 Setup 3 11 Setup procedure 2 5 Shutdown 3 16 Shutdown machine 3 16 Slitter 3 12 Specifications Dimensions 6 1 Installation requirements 6 1 Main roll opening 6 1 Main rolls 6 1 Material 6 1 Options 6 1 Speeds 6 1 Weight 6 1 Speeds 6 1 Splicing Paper 3 14 Vinyl 3 14 T Technical support Call 1 608 246 8844 or fax 1 608 246 8645 4 4 U Unpacking 2 4 Crate 2 4 Upper main roll 1 4 V Vinyl transfer 3 15 Vinyl transfer and overlamination materials 3 12 W Warnings and cautions 1 1 Warranty 5 1 Exclusions 5 1 7 2 GBC Pro Tech 1998 October
9. A WARNING Do not use liquid or aerosol cleaners on the image transfer laminator Do not spill liquid of any kind on the image transfer laminator You can be severely shocked electrocuted or cause a fire Use only a damp cloth for cleaning To clean the doors 1 Using a cotton terry cloth wash the doors using a mild soap or detergent and lukewarm water A IMPORTANT Do not scrub or use brushes or squeegees to clean the doors You can scratch the surface 2 Rinse thoroughly to prevent water spotting 3 To remove grease rub lightly with isopropyl alco hol then wash and rinse Compatible Cleaning Agents Fantastik e Formula 409 e Hexcel FO 554 2 Joy e Lysol e Mr Clean e Neleco Placer e PineSol e Top Job e Windex Registered Trademark of the Clorox Company 2 Registered Trademarks of Procter amp Gamble 2 Registered Trademark of Sterling Drugs Registered Trademark of American Cyanamid 5 Registered Trademark of the Drackett Products Company GBC Pro Tech 1998 October ORCA IV Image Transfer Laminator Operation Manual Lubrication Tools required 15 hex wrench High temperature grease or lithium grease Grease gun e Heavy weight gear oil Soft cloth To lubricate the image transfer laminator A IMPORTANT Do not lubricate the image transfer laminator when it is hot You can be burned A IMPORTANT Un
10. Always check all four buttons A IMPORTANT Never operate the image transfer laminator unless all of the emergency stop buttons are functioning properly You can be crushed or burned QD Are the emergency stop kick cables working With the laminator running step on or kick the front emergency stop kick cable The rolls should stop turning and rise if they are lowered Reset the kick cable button See Figure 1 3 Kick Cable Reset Button to locate the kick cable reset button Then reset the main machine reset See Figure 1 4 Machine Reset Button to locate the main machine reset button A IMPORTANT Never operate the image transfer laminator unless both of the emergency stop kick cables are functioning properly You can be crushed or burned GBC Pro Tech 1998 October ORCA IV Image Transfer Laminator Operation Manual Q Is the safety system on the doors functioning Open any door of the image transfer laminator The rolls should slow to 3 0 ft min 1 m min with the doors open You should not be able to increase the speed of the machine above 3 0 ft min 1 m min t Note The speed control works best with a slow gradual increase or decrease of the speed control knob A IMPORTANT Never operate the image transfer laminator unless safety system on the doors is functioning properly You can be crushed or burned L Is the motor functioning Test the motor at various speeds ran
11. Cable Tripped Mechanism Correctly Seated 3 The bolts that hold the switch to the bracket are slotted and can be used to fine tune the switch adjustment Loosen the bolts tighten them until snug make the necessary adjustments then lock them down securely GBC Pro Tech 1998 October Maintenance and Troubleshooting ORCA IV Image Transfer Laminator Operation Manual Contacting Technical Support For machine parts and technical service in North America please call 1 608 246 8844 or fax 1 608 246 8645 Please provide serial number when call ing for service In Europe please call 44 0 1844 202 440 or fax 44 0 1844 202 441 For film and application questions in North America please call 1 608 246 8844 or fax 1 608 246 8645 In Europe please call 44 0 1844 202 440 or fax 44 0 1844 202 441 4 4 GBC Pro Tech 1998 October ORCA IV Image Transfer Laminator Operation Manual Maintenance and Troubleshooting Grease Fitting Grease Fitting Keep Pins 3 Well Oiled Monthly Disassemble and Grease Yearly Lubricate Slides with Grease Fitting Grease iy E 113 c mi Pull Roll y S Grease Both BM zx Sides Bottom Roll Grease Main Roll Bearings Both Sides Top and Bottom Rolls Grease Fitting Grease Fitting Figure 4 1 Grease Fittings GBC Pro Tech 1998 October 4 5 Maintenance and Troubleshooting ORCA IV Image Transfer Laminator Operation M
12. Signal Meaning Continuous rapid beep If the roll is down but not turning the machine will begin beeping con tinuously after 10 sec onds Four beeps every 30 sec onds after 55 minutes of inactivity If the roll is up and the heater is on the machine will begin beeping four times every 30 seconds after the machine has been inactive for 55 minutes One beep per second The machine is in reverse GBC Pro Tech 1998 October Operation ORCA IV Image Transfer Laminator Operation Manual Operator Controls The operator controls for the ORCA IV Image Transfer Laminator are located on the front and rear of the machine to the right of the operator positions The names and functions of these controls are as follows Front Control Panel g Roll Temperature Adjustment Displa Main Rol 1 Pressure Display 9 Roll Heat 2 ON OFF Main Roll 2 UP DOWN 3 4 L8 puit Roll Main Roll UP DOWN P nt justmen Preheater 4 O O 1 ON OFF O 4 optional ES E Cooling Fan ON OFF 12 Preheater Temperature Adjustment Displa 13 optional GBC Logo Preheater Heat Automatic Manual 4 ON OFF Mode Control Accumulator Speed A 15 y ap T Display Toggle 7 16 5 Motion Control m CLIS peter con STOP REVERSE Figure 3 5 Front Control Panel 1 MAIN ROLL PRESSURE DISPLAY Displays the air pressure pushing the upper main r
13. are being used ORCA IV Image Transfer Laminator Operation Manual Setting the Slitter 1 Turn the thumbscrew on the slitter counterclock wise until it stops Figure 3 9 Slitter 2 Turn the thumbscrew one turn clockwise Set the slitter blade against the plastic covered black roll 4 Engage the slitter against the tube by allowing the slitter to just touch the tube and then pressing it 1 16 further Note Setting the slitter to tight shortens the life of the blade and the plastic tube 5 Pull the material through the machine to test the slitter Adjust the thumbscrew to obtain the required results Paper Tips e Always cut the leading edge of a print straight so it can be fed perpendicular to the rolls e The paper must be trimmed to match the width of the vinyl e The paper will wrinkle if it extends more than 1 2 beyond the vinyl edge e The trim can be neatly collected by threading it behind the imaged transfer media roll and taping it to the used transfer media core just to the outside of the trimmed transfer media The diameter of the collected trim must be kept the same as the diame ter of the winding transfer media to obtain a good quality windup e When trimming the final product the trim can be wound on the same core just outside of the edge of the roll 3 12 GBC Pro Tech 1998 October ORCA IV Image Transfer Laminator Operation Manual Positioning the Film and Centering
14. controller to see or change the set point 9 ROLL HEAT ON OFF Turns the heater control ler for the top roll on or off 10 PULL ROLL UP DOWN Sets the pull roll to the up load or down operate position 11 COOLING FAN ON OFF Turns the cooling fan on or off Push once to turn only the cooling idlers on push again to turn only the cooling tubes on push a third time to turn both cooling idlers and cooling tubes on and push a fourth time for all cooling off 12 PREHEATER AIR TEMPERATURE optional Provides a readout of the temperature of the air inside the preheater and the set point for the desired temperature 13 PREHEATER HEAT ON OFF Turns the heater controller in the preheater roll on or off 14 ACCUMULATOR RESET Resets the accumu lator 15 SPEED ACCUMULATOR TOGGLE Toggles control between the speed and the accumulator 16 MOTION CONTROL FORWARD STOP REVERSE Controls the direction of the drive system forward reverse or stop Operation GBC Pro Tech 1998 October Operation Front Clutch Brake Panel ll 5 2 Upper Middle Clutc Rewind Pressure N 3 Upper Middle Clutch Rewind I Upper Middle Clutc Rewind Indicator Percent Web 5 Upper Front Clutct Rewind Pressure N a6 mum o rm Upper Front A Clutch Rewind Percent Web Force p Force Upper Front Clutct Rewind Indicator j LE Middle Front Brake Pressure iN a9 Middle Front Middle F
15. down operate position PULL ROLL PRESSURE CONTROL Varies the air pressure fed to the cylinders that drive the upper pull roll down GBC LOGO AUTOMATIC MANUAL MODE CONTROL Toggles between Automatic Tension and Manual Tension mode In Automatic Tension mode the system automatically adjusts the brake clutch pressure In Manual Tension mode the sys tem doesn t automatically adjust these pressures indicated by an H or L in the accumulator dis play In the Automatic Tension mode with the motor stopped setting a web force tension for either a clutch or brake loads that force into the internal computer which then automatically adjusts the air pressure sent to the clutch brake to obtain the reguired web tension based on the roll size When you enter the setting and then turn the motor on the indicator changes from reading the web force to the actual pressure sent to the brake to attain the reguired web force calculated for that roll size In Manual Tension mode the display reads actual pressure sent to the clutch brake This pres sure stays set until you change it The computer will not override your setting or change the display ORCA IV Image Transfer Laminator Operation Manual 5 SPEED ACCUMULATOR DISPLAY Dis plays either the accumulator or speed depending on which you have selected with the SPEED ACCUMULATOR TOGGLE A letter in the dis play before the speed readout indicates the mode of
16. kick cable is activated or when the power to the machine is turned on 1 Make sure all emergency stop buttons and kick cables are reset 2 Press the main machine reset button above the power switch on the back of the machine See Fig ure 1 4 Machine Reset Button 3 Check the web force settings to make sure they are what you require 4 Turn the heater back on It is necessary to restart the heater as all power is turned off when an emer gency stop button or kick cable is activated 5 Lock the shafts by closing the doors of the machine and pressing either the shaft locking switch or the FWD or REV arrow 6 Start the motor and increase the speed Note If the display does not have a decimal point in it the machine needs to be reset Safety Power Switch w Lock Reset Button P Power Switch Lockout A Figure 1 4 Machine Reset Button Despite the safety features built into the ORCA IV extreme caution must be used when operating or ser vicing the unit READ THE FOLLOWING WARN INGS AND CAUTIONS BEFORE ATTEMPTING TO OPERATE OR SERVICE THE ORCA IV IMAGE TRANSFER LAMINATOR A WARNING Secure long hair so that it cannot get caught in the machinery Do not wear ties loose fitting clothing or dangling jewelry while cleaning or servicing the image transfer laminator These items can get caught in the nip and choke you or you can be crushed or burned A IMPORTANT Use a lift to load and u
17. pull roll COOLING FAN ON OFF Turns the cooling fan on or off Push once to turn only the cooling idlers on push again to turn only the cooling tubes on push a third time to turn both cooling idlers and cooling tubes on and push a fourth time for all cooling off GBC Pro Tech 1998 October ORCA IV Image Transfer Laminator Operation Manual Operation 12 ACCUMULATOR RESET Resets the accumu lator 13 SPEED ACCUMULATOR TOGGLE Toggles control between the speed and the accumulator 14 MOTION CONTROL FORWARD STOP REVERSE Controls the direction of the drive system forward reverse or stop GBC Pro Tech 1998 October 3 9 Operation Rear Clutch Brake Panel Upper Rear Brake i Percent Web Force 7 Upper Rear Brake 3 2 Upper Rear Brake l Pressure N EB Indicator Middle Rear Clutch Pressure 7 Middle Rear Clutch Indicator Middle Rear Clutch bi Percent Web Force Lower Rear Clutch 7 Lower Rear Clutch Pressure Percent Web Force q Lower Rear Clutch Indicator Unwind Rewind 124 Shaft Locking System ON OFF GBC morc Figure 3 8 Rear Brake Panel UPPER REAR BRAKE PERCENT WEB FORCE Indicates the web force tension for this brake as a percentage of the total possible tension the brake can exert What the pressure indicator displays changes depending upon whether the motor is on or off and what mode you are operating the machine under With the m
18. realignment GBC Pro Tech s warranty does not cover malfunction of the equipment due to mishandling and or tipping GBC Pro Tech bears no responsibility for personal injury or damage due to moving the 9 Carefully remove any accessories packed with the machine The accessory pack should contain 1 Towel white 1 Slitting knife 1 Set hex wrenches 4 Leveling pads 3 Fuses 6A 250V 1 Tape measure 1 Rubber cement pick up 1 Strain relief 1 Manual 4 Slitter Assemblies 2 T handle wrenches ln 2 Web unwind spacers 10 Remove any plastic strapping and packing paper taped to the rolls A IMPORTANT Do not use a knife or other sharp instrument during installation or while servicing the image transfer laminator You can cause irreparable damage to the rolls image transfer laminator improperly 11 Remove all packing materials to a safe distance from the image transfer laminator 12 Level the machine using the procedure included in this section GBC Pro Tech 1998 October ORCA IV Image Transfer Laminator Operation Manual c NOTE A word about international shipments As these are heavy pieces of equipment GBC Pro Tech takes every precaution to ensure that our image transfer lamina tors are properly crated to the highest standards Before machines leave our loading dock they are pre treated with a VCI protective film to provide total cor rosion protection This protective fil
19. requires filtered dry air at 1 5 cubic feet per minute cfm 50 liters minute at a pressure of 100 pounds per square inch psi 700 kPa The air supply must be clean free of dirt and dry Moisture causes corrosion and particles block pneumatic controls Either problem can cause the laminator to malfunction It is the customer s responsibility to provide appro priate filters and water traps for the air hose before the air is routed to the laminator Pro Tech suggests that the best approach to the air requirement is to provide a dedicated small compressor for the lami nator A standard light duty 1 2 to horse power 1 kW electric air compressor with 1 5 to 2 5 cfm output with a 5 gallon 20 liter storage tank is appropriate A IMPORTANT The air supply to the laminator must be clean and dry or the machine will be damaged ORCA IV Image Transfer Laminator Operation Manual GBC Pro Tech 1998 October ORCA IV Image Transfer Laminator Operation Manual Installation A 4x6 1 2m x 2m Work Table on Wheels Electrical Supply Standard Inlet on Bottom of A Machine 50 ET Air Supply On Bottom of 24 Machine 7 3m lt gt 4x6 1 2m x 2m Work Table on Wheels Y lt lt 20 6m gt Figure 2 6 Machine Space Reguirements GBC Pro Tech 1998 October 2 3 Installation Unpacking c NOTE ALL SHIPMENTS ARE EX WORKS At our dock title passes
20. rolls Use care in lowering the top main roll and know how to react quickly in an emergency The laminator roll UP DOWN switch is located on the instrument panels This switch controls the up and down motion of the top laminator roll Before pressing this switch to the DOWN position ensure that nothing is in the nip area If any problem or danger should occur depressing any of the emergency buttons stops the rolls from closing and raises them completely t Note To quickly stop the machine in the event of an emer gency press any of the emergency stop buttons or apply force to either kick cable This action stops the machine completely and raises the rolls In addition the rolls of the ORCA IV can reach tem peratures of over 290 F 143 C At these tempera tures you can be burned if the rolls are touched during set up operation or servicing Opening any door of the image transfer laminator causes the rolls to slow to 3 0 ft min 1 m min A WARNING Do not ever attempt to override the safety system on the doors of the machine or the kick cables You could get your fingers or arms between the rolls when they are turning or in the closed position and you could be crushed or severely burned The machine has a steel cabinet that is bolted closed to isolate the electrical and drive system components for the safety of the operator Only a qualified service tech nician should open these cabinets GBC P
21. the Web Tools required ly 4 T handle wrench Tape measure To load film 1 Retract the shaft locking plungers and remove the shafts Slide the shaft into the new roll of material until the end plate is tight to the end of the material Always leave the end plate on the drive side locked down This insures that the material alignment will be the same from roll to roll See the material size chart to determine what end plate setting to use for differ ent width materials Make sure the end plates are tight to the edge of the material If the core protrudes out more than 1 8 it will be necessary to use a plastic spacer to fill the gap Provided in the accessory pack Place the roll of material on the machine Be sure to line up with the drive tang and slide the shaft over to engage it into the drive tang Make sure the shafts are slid over and engaged This is critical to prevent the material from shifting after the machine is webbed Repeat steps 1 through 4 for the unwinds and rewinds When all the material is loaded on the unwinds and all the empty cores are loaded on the rewinds close the doors and lock in the shafts Open the doors and verify that the paper edge matches the edge of the vinyl by measuring from the side plate to the edge of the rolls If the paper or vinyl do not match up loosen the end plates and adjust the material so they are exactly in line Web the vinyl as shown in the diagram and secu
22. through the nip If slitters are being used be sure uct and process Process control charts are an excellent that they have cut through the two layers of paper tool for training new operators They provide a road and the tape at the splice It is best to run slow as map for correct machine setup and operation the splice passes through the slitters and finish the This section contains a completed chart for the basic cut if necessary operation of the image transfer laminator GBC Pro Tech image transfer laminators respond in a very accurate and repeatable manner The chart pro vides a way to set up each time every time for repeat able performance by assuring that all controls are set to optimum The process control chart should be kept in this manual or in a book close to the image transfer laminator gt NOTE When trying new products and processes remember that GBC Pro Tech s customer service representatives are only a phone call away In North America call 1 608 246 8844 or fax 1 608 246 8645 Vinyl Transfer Setup 1 See process chart 3 1 and diagram 3 1a on page 3 17 Figure 3 10 Splicing Paper 2 Set the controls as follows e Main Roll Air Pressure 100 psi 689 kPa e Pull Roll Clutch Air Pressure 35 psi 241 kPa e Pull Roll Up Down Down e Pull Roll Air Pressure 80 psi 552 kPa e Speed Adjust 1 10 fpm 3 3 0 m min e Upper Heater Controller 290 F 143 C e Cooling Idlers on cooli
23. 0 ft min 1 m min Operation A WARNING Do not ever attempt to override the safety system on the doors of the machine or the kick cables You could get your fingers or arms between the rolls when they are turning or in the closed position and you could be crushed or severely burned The machine has a steel cabinet that is bolted closed to isolate the electrical and drive system components for the safety of the operator Only a qualified service tech nician should open these cabinets GBC Pro Tech 1998 October Operation The machine is equipped with four emergency stop buttons located on either side of the front and back of the image transfer laminator Any of these if engaged stops the machine To continue operation all emer gency stop buttons must be in the up position and you must perform the Machine Reset Procedure See Machine Reset Procedure on page 3 3 Twist each button to resume operation the button pops out Push any button to stop the laminator Figure 3 1 Using the Emergency Stop Buttons In addition the ORCA IV is equipped with two emer gency stop kick cables located at the lower front and back of the image transfer laminator ORCA IV Image Transfer Laminator Operation Manual FRONT A 14 A a Emergency Stop Kick Cable Emergency Stop Kick Cable
24. 13 Film SPACING EIE EOD A A 3 14 Operational Tips and TriCRS Lien dns orn poste eere tn De Ee eoo pest Ene eh bmx pec c 3 14 Changing Film and Papel s secat po eh ete olo ee RE deste ad to pb uetus 3 14 Process Control AAA t ep LI LL dtes ud 3 15 VINYTranstor arenal iia toi 3 15 A A O 3 15 PECES mre A o ne 3 16 Maciel tials 3 16 A o dy et a e eee td d u ee ceeds da ML C EU 3 16 GBC Pro Tech 1998 October ORCA IV Image Transfer Laminator Operation Manual Section 4 Maintenance and Troubleshooting mmmememmmenenenenenenennnnnne 4 1 ICANN Arkus sa us ak cea ate AR A Saro Ko MAN ES 4 1 LUIS FICATION pos ccc 4 3 Adjusting the Kick Cables tante nt RM as 4 3 Contacting Technical SUDDOFLE seco ca a A ida 4 4 Output Troubleshooting Gulde sc cecdeepseses dees csnne daras 4 6 Section 5 Warranty mmmmmememenennnnnennnnnenennnnnnnnnnnnnnnnnennnnnnnennnnnennnnnnnnnnnnnnn 5 1 ESC AT SD eco otk eee ht rad A ro 5 1 EXGIUSIONS tone Walla ss e p ette onte D E E Eie tude vai 5 1 Section 6 Specifications Leere nn 6 1 Section 7 Index mmmmenemennnnnennnenenennnnnennnnnnnnnnnnnnnnnnnennnnnnnennnnnnnnnnnnnnnnnnnnn 7 1 GBC Pro Tech 1998 October ORCA IV Image Transfer Laminator Operation Manual Section 1 Safety DO NOT ATTEMPT TO OPERATE YOUR ORCA IV IMAGE TRANSFER LAMINATOR UNTIL YOU HAVE READ THIS SECTION CAREFULLY Your safety as well as the safe
25. 4 10 GBC Pro Tech 1998 October ORCA IV Image Transfer Laminator Operation Manual Maintenance and Troubleshooting Problem Number Problem Possible Cause Corrective Action 25 I pressed the totalizer reset a Is the machine reset Reset the machine See Machine push button while in total b Is there a problem with the key Reset Procedure on page 3 3 ize modecanditdidaot pad Check tighten the connector to rasstand SP buttons o c Is there a software problem the keypad 11 Technical t the panel do not work either ee ce but the controls on the other panel work 26 My air supply is 100 psi but Has the display panel been cali Call Technical Support my control panel reads less brated Call Technical Support than 100 psi b Is the pressure transducer faulty 27 When I operate the machine This is a normal safety function No corrective action necessary in reverse an alarm goes off 28 An alarm sounds rapidly a Main rolls are down and the rolls Raise the rolls or run the machine after a 10 second delay are not turning at a slow speed to increase the life of the rolls 29 After 55 minutes of no activ The main roll is in the up position If you re not using the machine ity a 4 beep alarm sounds and the temperature controller is turn the temperature controller followed by a 30 second on off or lower the roll and run the dela machine at a slow speed Failure
26. DE A MISE EN GARDE WARNING SAFETY INSTRUCTIONS SICHERHEITS RICHTLINIEN CONSIGNES DE SECURITE Moving parts can crush and cut Do not operate with guard or door open WARNING Crush and burn hazard Stay clear of moving rollers Stop machine and raise roll before cleaning WARNING Carefully read Operator s Manual before handling this machine Observe instructions and safety rules when operating WARNING HAZARDOUS VOLTAGE lt 100 PSI 2700 KPa To be serviced only by trained and authorized personnel Lockout power before servicing CAUTION Surface is hot A burn hazard exists CAUTION Rolls are heavy Use proper lifting techniques to prevent injury CAUTION For continued protection against risk of fire replace only with same type and rating of fuse Machine identification label Meaning WARNING Read and understand the Operation Manual and all safety labels before operating this machine Only a trained person is to be permitted to operate this machine Training should include instruction in operation under normal conditions and emergency situations This machine is to be serviced only by trained and authorized personnel Follow lockout procedures before servicing Never reach into the machine for any reason unless the machine is at a COMPLETE STOP Never leave the machine stopped in
27. DIATELY using 80 isopropyl alcohol It can harden within an hour and ruin the roll A IMPORTANT Exercise care when cleaning the rolls with 80 or stronger isopropyl alcohol Use only in a well ventilated area Wear rubber gloves Use only on cool rolls Cleaning heated rolls can ignite the fumes A IMPORTANT The operating environment must be free of dust flammable liquids and vapors You can be injured by inhaling chemical vapors Vapor build up or stored flammable liquids can cause a fire Excessive dust can damage the image transfer laminator A IMPORTANT Do not use a knife or other sharp instrument during installation or while servicing the image transfer laminator You can cause irreparable damage to the rolls GBC Pro Tech 1998 October ORCA IV Image Transfer Laminator Operation Manual A IMPORTANT Safety A IMPORTANT Do not attempt to move the image transfer laminator across anything other than a flat level surface without trained and qualified riggers You can be crushed or seriously injured The ORCA IV Image Transfer Laminator is a large and heavy piece of equipment It is necessary to employ LICENSED RIGGERS ONLY to move the machine The image transfer laminator is not designed to be tipped up or sideways in any way Such action disturbs the exact alignment of the rolling parts of the machine and requires extensive realignment GBC P
28. Figure 3 2 Using the Emergency Stop Kick Cables Either of these if stepped on or kicked stops the lami nator and raises the rolls To continue operation press the kick cable reset button Then complete the Machine Reset Procedure See Machine Reset Procedure on page 3 3 GBC Pro Tech 1998 October ORCA IV Image Transfer Laminator Operation Manual Kick Cable Reset Button Figure 3 3 Kick Cable Reset Button Machine Reset Procedure Perform this procedure whenever an emergency stop button or kick cable is activated or when the power to the machine is turned on 1 Make sure all emergency stop buttons and kick cables are reset 2 Press the main machine reset button above the power switch on the back of the machine See Fig ure 3 4 Machine Reset Button 3 Check the web force settings to make sure they are what you require 4 Restart the heater if it is being used 5 Lock the shafts by closing the doors of the machine and pressing the shaft lock button or starting the motor Operation 6 Start the motor and increase the speed 7 7 m m m f 7 Y Reset Power Ps Switch Lockout Power Switch w Lock Figure 3 4 Machine Reset Button Audible Signals For your safety the machine has several audible signals that are used to alert you to the status of the machine The following table lists the alert signals Table 3 1 Audible Signals Audible
29. Graphic 20 WF Transfer Media 3M 8601i 15 WF Marking Film Vinyl Like 3M 8620 8640 etc 20 WF Overlaminate Unwind 50 WF Used Transfer Media Rewind 20WF Strip Release Liner Laminate 30 WF IMAGE TRANSFER LAMINATOR SETTINGS Top Heater Status 290 F 143 C Pull Roll Position Up or Down optional unless applying laminate Speed 1 10 fpm 3 3 0 m min max Main Roll Setting 100 psi 689 kPa Drive Direction Forward Output Cooling Idlers On Cooling Tubes Optional Drive Mode Automatic or Manual PROCESS CONTROL DIAGRAM 3 1A Over laminate Optional Paper Trim Rewind Finished Marking Graphic Film Front Input Notes GBC Pro Tech 1998 October 3 17 Operation ORCA IV Image Transfer Laminator Operation Manual Blank page 3 18 GBC Pro Tech 1998 October ORCA IV Image Transfer Laminator Operation Manual Section 4 Maintenance and Troubleshooting Performing regular maintenance on the ORCA IV Image Transfer Laminator is critical to the proper oper ation of the machine A maintenance schedule and a section of procedures for disassembling and reassem bling the serviceable areas of the image transfer lami nator are included in this section Table 4 3 Maintenance Schedule Clean the rolls and machine Daily Inspect the area around the image transfer laminator for possible haz a
30. ORCA IV Image Transfer Laminator Operation Manual 1998 GBC Pro Tech Do not duplicate without written permission GBC Pro Tech 4151 Anderson Road De Forest Wisconsin 53532 Tel 608 246 8844 Part Number 930 009 Rev A Fax 608 246 8645 ORCA IV Image Transfer Laminator Operation Manual The information in this publication is provided for reference and is believed to be accurate and complete GBC Pro Tech is not liable for errors in this publication or for incidental or consequential damage in connection with the furnishing or use of the information in this publication including but not limited to any implied warranty of fitness or merchantabil ity for any particular use GBC Pro Tech reserves the right to make changes to this publication and to the products described in it without notice All specifications and information concerning products are subject to change without notice Reference in this publication to information or products protected by copyright or patent does not convey any license under the rights of GBC Pro Tech or others GBC Pro Tech assumes no liability arising from infringements of patents or any other rights of third parties This manual is copyrighted 1998 by GBC Pro Tech All rights reserved The information contained in this manual is proprietary and may not be reproduced stored transmitted or transferred in whole or in part in any form without the prior and express w
31. afts over to the drive side to b Is there air pressure engage them b Check for appropriate main air supply or increase the air pressure to the rewind 10 Laminate paper rewind will a Is the pull roll up a Lower the pull roll The laminate not turn and or you cannot paper rewind will not turn and the set the pressure pressure will not increase until the pull roll is down b Stop the motor to allow the web force to be set 11 Roll is overheating a Is the IR sensor blocked a Be sure nothing ever blocks the b Is the IR sensor misaligned path of the IR sensor c Is there cool air blowing on the b Align the sensor roll c Direct the cool air away from the d Is there an electrical problem roll surface d Call Technical Support 4 8 GBC Pro Tech 1998 October ORCA IV Image Transfer Laminator Operation Manual Maintenance and Troubleshooting Harel Problem Possible Cause Corrective Action 12 I pressed the motor forward Has a speed setting been set a Press the FWD or REV arrow and button but the rolls would b Are the doors closed and shafts turn the speed control up nottut locked in b Close the doors and lock in the c Are the e stop buttons pressed unwind rewind shafts Are the kick cables reset c Make sure all safety buttons are d Is there decimal on display released out Be sure all kick e Check motor fuses on the back of cables are reset and adjusted
32. age Transfer Laminator Operation Manual Blank page 1 8 GBC Pro Tech 1998 October ORCA IV Image Transfer Laminator Operation Manual Section 2 Installation GBC Pro Tech is committed to a program of ongoing product improvement As a result we are providing these instructions so that you can ensure that your new ORCA IV Laminator is properly and securely unpacked moved and installed Before an ORCA IV Image Transfer Laminator can be installed there are a few requirements that must be met Make certain that each of the requirements listed in the following preinstallation checklist are met before beginning installation A IMPORTANT Failure to follow the preinstallation checklist can result in damage to the image transfer laminator Preinstallation Checklist L1 Are doorways and hallways wide enough for the image transfer laminator to be moved to the instal lation site Q Is there ample room for the image transfer lamina tor A work area must be established that allows for operation in both the front and the rear of the machine and provides space for efficient material flow See Figure 2 6 Machine Space Require ments for a typical machine area layout Q Is the environment appropriate for the image trans fer laminator The image transfer laminator requires a clean dust and vapor free environment to operate properly such as an air conditioned office area with forced 10 make up air However the ima
33. an exert What the pressure indicator displays changes depending upon whether the motor is on or off and what mode you are operating the machine under With the motor direction arrows off and the machine in Automatic Tension mode the indicator displays the material web tension you set Once the motor 10 ORCA IV Image Transfer Laminator Operation Manual arrow is pressed and the machine starts the com puter calculates the appropriate pressure to attain the required web force based on the roll size The indicator then changes to read the actual air pres sure in psi sent to the clutch brake If the machine is in Manual Tension mode the indicator reads the actual air pressure in psi sent to the clutch brake UPPER FRONT CLUTCH REWIND PRES SURE Adjusts the clutch pressure up or down UPPER FRONT CLUTCH REWIND INDI CATOR Indicates that this set of controls is for the upper front clutch MIDDLE FRONT BRAKE PERCENT WEB FORCE Indicates the web force tension for this brake as a percentage of the total possible tension the brake can exert What the pressure indicator displays changes depending upon whether the motor is on or off and what mode you are operating the machine under With the motor direction arrows off and the machine in Automatic Tension mode the indicator displays the material web ten sion you set Once the motor arrow is pressed and the machine starts the computer calculates the appropriate pressure to a
34. anual Output Troubleshooting Guide pe T Problem D waves in the image not in the laminate Hints Check paper tension Check relative moisture content of the paper N Problem Waves on only one side of the output Hints e Check nip settings e Check for even paper tension e Check for proper alignment on initial setup Direction A A Problem Problem D waves in the laminate Straight waves in the output Hints Hints Increase brake tension Decrease clutch tension on laminate Check operational settings for Check roll pressures materials being used Check nip settings Other Common Problems Feed Problem Blistering in the image Hints Increase speed or lower the operating temperature Problem Coiling of encapsulated images Hints Balance the upper and lower unwind brake tension Adjust cooling fans Problem Longitudinal waves or stuttering jerking or excessive noise from the drive side of the laminator Hints Increase chain tension decrease unwind brake tension 4 6 GBC Pro Tech 1998 October ORCA IV Image Transfer Laminator Operation Manual Table 4 4 Machine Troubleshooting Guide Maintenance and Troubleshooting Problem Number Problem Possible Cause Corrective Action 1 No display Is there power to the unit Check for power to the machine building circuit breaker is on main switch is on I and t
35. ation Manual Index Numerics 3M 3 12 A Accessory pack 2 4 Air supply 2 2 Audible signals 3 3 C Centering the web 3 13 Chain Lubrication 4 3 Changing film and paper 3 14 Cleaning 4 1 Cabinet and covers 4 2 Doors 4 2 Rolls 4 1 Controls Front brake panel 3 6 Front control panel 3 4 Rear brake panel 3 10 Rear control panel 3 8 Emergency stop buttons 1 2 2 6 3 2 Environment 2 1 F Film 3 12 Loading 3 11 Film spacing 3 14 Front clutch brake panel 3 6 Front control panel 3 4 FWD REV switch 4 2 G Grease fittings 4 3 Heater 2 7 Controller 2 7 Heating 3 11 Installation requirements 2 1 6 1 International shipments 2 5 Isopropyl alcohol 4 1 J Jumper configurations 2 1 K Kick cable 1 2 2 6 Adjusting 4 3 L Laminate adhesives 3 12 Leveling 2 5 Lubrication 4 3 Main roll opening 6 1 Main rolls 6 1 Maintenance schedule 4 1 Material 6 1 Motor 2 7 N Nip 1 1 1 3 3 1 O Options 6 1 P Paper 3 12 Positioning the film 3 13 Preinstallation checklist 2 1 Process control charts 3 15 Rear clutch brake panel 3 10 Rear control panel 3 8 Recommended materials 3 12 Reset button 1 3 Reset procedure machine 1 3 Reset machine 3 3 Rexam 3 12 Riggers 1 5 2 4 Roll to roll transfer 3 15 Rubber cement eraser 4 1 GBC Pro Tech 1998 October ORCA IV Image Transfer Laminator Operation Manual S Safety 1 1 Safety features 6 1 Safety hazard decals 1 7 Safety information 1 1
36. e indicator reads the actual air pressure in psi sent to the clutch brake Note that this clutch laminate paper rewind only operates when the pull roll is down MIDDLE REAR CLUTCH PRESSURE Adjusts the clutch pressure up or down MIDDLE REAR CLUTCH INDICATOR Indi cates that this set of controls is for the middle rear clutch LOWER REAR CLUTCH PERCENT WEB FORCE Indicates the web force tension for this clutch as a percentage of the total possible tension the clutch can exert What the pressure indicator displays changes depending upon whether the motor is on or off and what mode you are operating the machine under With the motor direction arrows off and the machine in Automatic Tension mode the indicator displays the material web ten sion you set Once the motor arrow is pressed and the machine starts the computer calculates the appropriate pressure to attain the required web force based on the roll size The indicator then changes to read the actual air pressure in psi sent to the clutch brake If the machine is in Manual Tension mode the indicator reads the actual air pressure in psi sent to the clutch brake LOWER REAR CLUTCH PRESSURE Adjusts the clutch pressure up or down LOWER REAR CLUTCH INDICATOR Indi cates that this set of controls is for the lower rear clutch UNWIND REWIND SHAFT LOCKING SYS TEM ON OFF Engages disengages the unwind rewind shaft locking system The switch disen gages the locki
37. e laminating rolls A IMPORTANT Do not use compressed air to clean the machine Blowing debris can be forced into places where it will later ignite or short electric circuits GBC Pro Tech 1998 October Maintenance and Troubleshooting To clean beads of adhesive dust and dirt from the rolls 1 Allow the image transfer laminator to cool slightly to no higher than 110 F 43 C 2 Set the FWD REV switch to the REV position and let the rolls move slowly as you clean them Set the Speed Control to 1 5 ft min 3 Clean the rolls using a moderate amount of 80 isopropyl alcohol on a cotton terry cloth A IMPORTANT Use the minimum amount of pressure necessary to clean the rolls You can destroy the silicone layer on the rolls by pressing to hard or scrubbing too long in one spot A IMPORTANT Exercise care when cleaning the rolls with 80 isopropyl alcohol Use only in a well ventilated area Wear rubber gloves Use only on cool rolls Cleaning heated rolls can ignite the fumes A IMPORTANT Use only 80 isopropyl alcohol or a rubber cement eraser to clean the laminating rolls Harsh chemicals like toluene acetone or MEK destroy the silicone covering of the rolls ORCA IV Image Transfer Laminator Operation Manual To clean the cabinet and covers 1 Using a damp cotton terry cloth water only clean the exterior of the image transfer laminator
38. e splice and reduce leader waste e To get past a large white spot a known extra or a bad image on a roll of images The key to advancing the paper without the vinyl is to raise the main roll but let the material continue to run through until the paper that is not stuck to the vinyl clears the paper peal idler Then put the machine in reverse briefly to release tension on the paper peal idler or release the pull roll clutch and turn it back by hand Lower the paper unwind and rewind tension and hand turn the paper roll so that the paper is advanced without the vinyl advancing To advance the vinyl without the paper Release all the tension on the transfer media web Start the vinyl web If the paper is not stuck to the vinyl only the vinyl web will advance Changing Film and Paper The recommended way to change over to new material is to splice the new material to the old and let the old material web pull the new material through the machine To splice vinyl When splicing the vinyl stop the machine before the roll is totally used up 1 Load a new roll of vinyl on the unwind shaft and place it on the machine Engage the shaft into the drive tang 2 The old material should be left long enough to lay over the new roll This provides a straight firm surface to splice onto 3 Tape the new material to the old with a high quality 1 1 2 to 2 masking or vinyl tape Make sure the materials are straight before applying t
39. edures and safety features of the image transfer laminator before using or servicing the unit The GBC Pro Tech ORCA IV is a powerful machine that is designed for vinyl transfer and over lamination The forces required to accomplish these tasks are very large The air cylinder system used to provide downward pressure on the top roll is capable of producing forces greater than 1000 pounds 454kg This force is applied to any object presented in the opening called the nip between the two rolls Use care in lowering the top main roll and know how to react quickly in an emergency The laminator roll UP DOWN switch is located on the instrument panels This switch controls the up and down motion of the top laminator roll Before pressing this switch to the DOWN position ensure that nothing is in the nip area If any problem or danger should occur depressing any of the emergency buttons stops the rolls from closing and raises them completely v Note To quickly stop the machine in the event of an emer gency press any of the emergency stop buttons or apply force to either kick cable This action stops the machine completely and raises the rolls In addition the rolls of the ORCA IV can reach tem peratures of over 290 F 143 C At these tempera tures there is a danger of a severe burn if the rolls are touched during set up operation or servicing Opening any door of the image transfer laminator causes the rolls to slow to 3
40. epending on which you have selected with the SPEED ACCUMULATOR TOGGLE A letter in the dis play before the speed readout indicates the mode of operation H Manual mode with the preheater off P Automatic mode with the preheater on L Manual mode with the preheater on No letter Automatic mode with the preheater off The following codes alert you to machine status 0 The machine is reset and ready to be started 8888 Main power has just been turned on and the main reset has not yet been pressed In addition to these codes if an emergency stop button or kick cable is activated the decimal point will no longer be displayed for example 3 0 would change to 3 0 Simply resetting the emergency stop button or kick cable does not change the display You must also press the main machine reset button for display to read 0 indicating the machine is ready to be started Note that you must reset the emergency stop button or kick cable before press ing the main machine reset or the machine will not be reset SPEED ADJUSTMENT Adjusts the speed of the machine from zero to maximum as the control is turned clockwise Adjust the speed control slowly for best results GBC Pro Tech 1998 October ORCA IV Image Transfer Laminator Operation Manual 8 ROLL TEMPERATURE Provides a readout of the temperature of the upper main roll and the set point for the desired temperature adjustment Press the star button on the temperature
41. es not cover damage to the laminating rollers caused by knives razor blades other sharp objects failure caused by adhesives or improper use of the machine Warranty repair or replacement does not extend the warranty beyond the initial period from the date of delivery A IMPORTANT Unauthorized customer alterations will void this warranty THE WARRANTY MADE HEREIN IS IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING ANY WARRANTY OR MERCHANTABILITY OR FITNESS FOR A PAR TICULAR PURPOSE GBC PRO TECH WILL NOT BE LIABLE FOR PROPERTY DAMAGE OR PER SONAL INJURY UNLESS PRIMARILY CAUSED BY ITS NEGLIGENCE LOSS OF PROFIT OR OTHER INCIDENTAL OR CONSEQUENTIAL DAMAGES ARISING OUT OF THE USE OR INABILITY TO USE THE EQUIPMENT Warranty Exclusions to the Warranty This warranty specifically does not cover 1 Damage to the laminating rolls caused by knives razor blades other sharp objects or failure caused by adhesives 2 Damage to the machine caused by lifting tilting and or any attempt to position the machine other than rolling on the installed casters on even sur faces 3 Improper use of the machine GBC Pro Tech 1998 October Warranty ORCA IV Image Transfer Laminator Operation Manual Blank page 5 2 GBC Pro Tech 1998 October ORCA IV Image Transfer Laminator Operation Manual Section 6 Specifications Table 6 1 ORCA IV Image Transfer Laminator Specifications
42. f these labels GBC Pro Tech 1998 October Safety ORCA IV Image Transfer Laminator Operation Manual AWARNING Located One Located At Inside Each Roll Load A ACHTUNG Cabinet Point 7 Total MISE EN GARDE ik BO Located Inside e Cabinet CAUTION EXPOSED ROLLER Can ca Keep h an sae Located Inside Cabinet e WARNING i A ACHTUNG AA MISE EN GARDE 1 0000 a 0609 n o Located Inside On Cabinet Exterior i Panels Located Inside 2 Cabinet HIGH LEAKAGE CURRENT Earth ction tial before connecting supply SEE INSTALLATION INSTRUCTIONS Model No BEFORE CONNECTING TO THE SUPPLY Phase Emergency Stop Kick Cables Located Below Kick or Step on to Stop Laminating Process Located On Door lt 100 PSI 2700 KPa SAFETY INSTRUCTIONS SICHERHEITS RICHTLINIEN CONSIGNES DE SECURITE Figure 1 5 Locations of Safety Labels 1 6 GBC Pro Tech 1998 October ORCA IV Image Transfer Laminator Operation Manual Safety The following are typical safety hazard decals used on GBC Pro Tech machines with a brief description Mean ing column of each decal AWARNING A ACHTUNG A MISE EN GARDE ik WARNING AWARNING ACHTUNG A ACHTUNG A MISE EN GAR
43. ge transfer lam inator must not be located where there is air blow ing directly on it Major fluctuation in temperature and humidity are to be avoided Installation A IMPORTANT The operating environment must be free of dust flammable liquids and vapors You can be injured by inhaling chemical vapors Vapor build up or stored flammable liquids can cause a fire Excessive dust can damage the image transfer laminator A IMPORTANT Do not locate the image transfer laminator where air is blowing directly on the machine The air flow can cool the rolls unevenly and result in poor quality output L Have you contacted a certified electrician to both hard wire the laminator and ensure that an adequate power supply having the appropriate capacity overcurrent protection and safety lockouts is avail able The laminator requires 4 wire North American Delta 230 VAC 50 60 Hz three phase 45A per phase with the preheater option and 35A per phase without the preheater option t Note If you require setup for European power input three phase wye please contact GBC Technical Support koma Do not ever attempt to change the internal jumper configurations Only a gualified GBC Service Technician can change these configurations You can severely damage the machine GBC Pro Tech 1998 October Installation a Is there an appropriate filtered dry air supply avail able The machine
44. ging from 0 19 ft min 0 5 8 m min At 0 the rolls should stop turning Run the motor in both forward and reverse In reverse you should hear a beep once a second to alert you that you are operating the machine in reverse 1 Are the heaters working Verify that the heater controller heats the top roll The bottom roll cannot be heated Q Is the temperature set correctly Check that the temperature is set to 290 F 143 3 C for most transfer processes A IMPORTANT Never allow any film packing material object etc to block the infrared temperature sensor The sensor has a cone shaped view of the roll that should never be obstructed Severe roll damage can occur Installation carton Never allow loose objects pens knife blades jewelry etc close to the machine or web paths These objects can fall onto the web and can be carried through to the roll Severe roll damage can occur Once you have completed the startup checklist you can safely run a test sample GBC Pro Tech 1998 October Installation ORCA IV Image Transfer Laminator Operation Manual Blank page 2 8 GBC Pro Tech 1998 October ORCA IV Image Transfer Laminator Operation Manual Section 3 Operation Safety The ORCA IV Image Transfer Laminator has been designed with safety as a primary consideration How ever you must become thoroughly familiar with the controls proper operation proper service proc
45. he machine circuit breaker is on up Display reads 8888 Is the machine reset Make sure all safety buttons are released out Be sure all kick cables are reset and adjusted properly Press the machine reset above main switch See Machine Reset Procedure on page 3 3 Display reads 0 and the machine does not run Is the direction indicator FWD REV pressed Is the speed not turned up Press FWD or REV Turn up the speed control Display missing the decimal point e g reads 30 instead of 3 0 Is there a kick cable or safety but ton that has not been reset Make sure all safety buttons are released out Be sure all kick cables are reset and adjusted properly Press the machine reset above main switch See Machine Reset Procedure on page 3 3 Display missing the decimal point e g reads 30 instead of 3 0 but the kick cables and safety buttons have been checked and the reset button has been pushed Is the kick cable stretched out of adjustment Verify that the kick cable is truly resetting listen look Adjust the kick cable See Adjusting the Kick Cable on page 4 3 Waiver on one side of paper vinyl Is the tension too low Does the roll lower unevenly Was there a misalignment on set up Is there a bad roll of material Is the web loose only when first starting or splicing Is there uneven nip pressure Increase appropriate brake ten
46. he tape so that one side is not looser than the other 4 Start the tape in the center and work outward Lower the brake tension until the splice has cleared the main roll t Note On machines without the preheater option it is possible to splice the two materials together using the bottom main roll as the firm straight taping surface To splice paper Splicing paper is also the recommended way to change over to new material The key to a successful splice is to leave enough of the old paper to be able to wrap it on the new roll and tape it on a square firm surface 1 Load the new roll of transfer paper on the machine 2 Pullthe old paper around the roll of images and tension and smooth out evenly 3 Overlap the old paper with the new paper and tape securely It is very important to have the new mate rial over the old so that when the paper is peeled off later the new paper is lifted along with it and does not pull the tape off 3 14 GBC Pro Tech 1998 October ORCA IV Image Transfer Laminator Operation Manual Operation 4 Tape starting in the center and move to the sides Process Control Charts The tighter and smoother the tape job the less web looseness that will have to be tensioned out later PORS CORICOEGRAFISSSITON TOU tO reanl i wy you thread film through the machine s rolls and idlers 5 Decrease the brake tension until the splice passes called webbing and the control settings for each prod
47. ient S100 psi not go down b Is there at least 20 psi on the b Increase the pull roll air pressure gauge c Disconnect and reconnect air c Is the roll hook retracted pressure to the machine and d Are the e stop push buttons observe pull roll locking mecha pressed and the kick cables reset nism e Is the machine reset d See problem 12 e Reset the machine See Machine Reset Procedure on page 3 3 GBC Pro Tech 1998 October 4 9 Maintenance and Troubleshooting ORCA IV Image Transfer Laminator Operation Manual Problem Number Problem Possible Cause Corrective Action 17 I pressed the pull roll up Is there air pressure to the a Verify that the air supply is suffi push button but the rolls did machine cient S100 psi not go up Is the machine reset b Reset the machine See Machine Reset Procedure on page 3 3 18 I pressed the top roll temper Are the e stop push buttons a See problem 12 ature control ON push but pressed and the kick cables reset b Reset the machine See Machine ton and nothing happens Is the machine reset Reset Procedure on page 3 3 Is there a decimal point in the dis c Reset the machine See Machine play Reset Procedure on page 3 3 19 The display shows unusual Is the machine reset a Reset the machine See Machine numbers or characters Reset Procedure on page 3 3 20 I press the preheater push Th
48. is is normal This shows that a If you press the preheat button button and a P is displayed you are in PREHEAT AUTO again it will go off on the control panel mode 21 I pressed the cooling fan Is the cooling fan toggle switch a The cooling fan push button is a push button and the fan did set correctly 4 way toggle switch keep push notturni ORE ing the button until the fan goes off From the off position press once to turn only the cooling idler on press twice to turn the cooling tubes only on press a third time to turn on both the cooling idler and the cooling tubes and press a fourth time to turn the cooling systems off 22 I pressed the cooling fan Are the e stop push buttons a See problem 12 push button and the fan did pressed and the kick cables reset b Reset the machine See Machine GE ELON Is the machine reset Reset Procedure on page 3 3 23 I pushed the totalizer push Is the proximity switch that reads a Make adjustment and try again button the display changed the motor sensor teeth adjusted b If the input light comes on go to to read 4 characters but the prop erly ere problem 48 value does not increase Dogs the mput light T come on when the proximity switch comes on 24 I pressed the totalizer reset Is the machine reset a Reset the machine See Machine push button while in total Reset Procedure on page 3 3 izer mode and it did not reset and other buttons on the panel do not work either
49. is pulled off become enlarged from many cuts in a close area This causes the edge of the paper to go around a larger diameter at the slitter sta tion and causes small tears in the paper s edges which can lead to the paper starting to tear all the way across at the rear idler The solution is to sand file down the frequently used raised areas on the slitter s plastic tube 4 12 GBC Pro Tech 1998 October ORCA IV Image Transfer Laminator Operation Manual Section 5 Warranty Limited Warranty GBC Pro Tech Engineering Company Inc warrants the equipment sold is free from defects in material and workmanship for a period of one year from the date of delivery to the customer for parts and ninety days 90 from the date of delivery to the customer for labor This warranty is the only warranty made by GBC Pro Tech and cannot be modified or amended GBC Pro Tech s sole and exclusive liability and the customer s sole and exclusive remedy under this warranty shall be at GBC Pro Tech s option to repair or replace any such defective part or prod uct These remedies are only available if GBC Pro Tech s examination of the product discloses to GBC Pro Tech s satisfaction that such defects actually exist and were not caused by misuse neglect attempt to repair unauthorized alteration or modi fication incorrect line voltage contaminated air supply or by fire accident flood or other hazard This warranty specifically do
50. m is wrapped around the machine and completely sealed In addition moisture absorbing silicone desiccant packs are packed inside the crate and machine cabinets Prior to start up of the machine you must remove the desiccant packs from each cabinet and discard DO NOT operate the machine with the desiccant packs inside the cabinets Setup Once the ORCA IV Image Transfer Laminator has been unpacked and moved into final position perform the following setup procedure Tools required hex wrench e Adjustable wrench Setup Procedure 1 Inspect the machine for any obvious shipping dam age 2 Remove the drive and control side cabinet covers with the Dn hex wrench by removing the screws securing the covers to the machine Lift the covers off 3 Inspect all the bolts and tighten any that were loos ened during shipping 4 Have a certified electrician wire the machine directly to a power source Connect the machine to the air supply Replace all cabinet covers Installation Leveling Tools required e Adjustable wrench e Carpenter s level or equivalent To level the laminator 1 Install the four level pads included in the acces sory pack on the ends of the foot bolts 2 Remove the rear idler so that you can place a car petner s level across the pull roll to the bottom main roll 2e Figure 2 7 Leveling Front to Rear 3 Level this side of the machine front to rear raising or lowe
51. ng system with the door either open or closed with one motor off The doors must be shut to engage the system If the doors are shut and the unwind rewind shafts are disengaged pushing the motion control engages them automatically Note the color coding on each shaft and the shaft loading tray Unwinds are marked with blue and rewinds are marked with red Always use the cor rect shaft in each loading position 3 10 GBC Pro Tech 1998 October ORCA IV Image Transfer Laminator Operation Manual Setup Setup of the ORCA IV Image Transfer Laminator is quick and straightforward when instructions are fol lowed exactly Loading the Film A IMPORTANT Use a lift to load and unload rolls larger than 50 yards They can weigh up to 500 Ibs and can crush you Film is loaded on the appropriate unwinds indicated by color coding Blue shafts and loading trays indicate unwinds red shafts and loading trays indicate rewinds The process of loading and aligning film is the same for both the top and the bottom unwinds rewinds 1 Be sure that rewind clutch shafts are in rewind positions loading trays and unwind brake shafts are in unwind positions so that the core gripping mechanism engages properly 2 Slide the shaft over until the drive tang fits in the slot before engaging the unwind rewind shaft lock ing system 3 Loosen the lock collar with a 1 4 hex wrench and center the material before webbing the machine
52. ng tubes as needed GBC Pro Tech 1998 October 3 15 Operation ORCA IV Image Transfer Laminator Operation Manual Procedure 1 See process chart 3 1 and diagram 3 1a for mate rial mounting instructions and machine adjust ments 2 Web the vinyl up around the bottom main roll and over to the pull roll Make sure the material is webbed straight and lower the pull roll to hold the vinyl 3 Web the paper through as shown in diagram 3 1a Often when paper is not on a core hand tension must be applied to the paper in order to maintain transfer quality until the end of the transferred image Machine Shutdown It is very important that the ORCA IV Image Transfer Laminator is shut down in proper manner If not the rolls can be damaged or destroyed A IMPORTANT Failure to follow this procedure can result in damage to the rolls Procedure 1 Raise the upper main roll and upper pull roll so that the rolls do not make contact with the bottom rolls 2 Turn off the main power to the machine 3 Disconnect the air supply to the machine if the machine is not to be used for the next several days A IMPORTANT The main and pull rolls must always be in the up position when the machine is not in use 3 16 GBC Pro Tech 1998 October ORCA IV Image Transfer Laminator Operation Manual Operation PROCESS CONTROL CHART 3 1 WEB FORCE SUGGESTED VALUES Main Product Rewind Finished
53. nload rolls larger than 50 yards They can weigh up to 500 Ibs and can crush you GBC Pro Tech 1998 October Safety A IMPORTANT ORCA IV Image Transfer Laminator Operation Manual A IMPORTANT Do not operate the image transfer laminator near water You can be severely shocked electrocuted or cause a fire Raise the upper main roll when the image transfer laminator is not in operation Prolonged contact can damage the rolls Zas IMPORTANT Remove and lockout power from the image transfer laminator before servicing You can be severely shocked electrocuted or cause a fire Do not leave the top roll heater on with the roll raised Heat builds up in a stationary roll and can damage it A IMPORTANT IMPORTANT Do not use liquid or aerosol cleaners on the image transfer laminator Do not spill liquid of any kind on the image transfer laminator You can be severely shocked electrocuted or cause a fire Use only a damp cloth for cleaning Excess pressure can damage the rolls Always select the minimum roll pressure necessary to complete the task A IMPORTANT A IMPORTANT Use only 80 or stronger isopropyl alcohol or a rubber cement eraser to clean the rolls Harsh chemicals like toluene acetone or MEK destroy the silicone covering of the rolls If silicone adhesive contacts the upper or lower roll remove it IMME
54. oll down 2 MAIN ROLL UP DOWN Sets the upper main roll to the up load or down operate position 3 MAIN ROLL PRESSURE CONTROL Varies the air pressure fed to the cylinders that drive the upper main roll down 4 PREHEATER ON OFF optional Turns on or off the preheater The preheater mode is indicated by a P in the accumulator display 5 GBC LOGO AUTOMATIC MANUAL MODE CONTROL Toggles between Automatic Tension and Manual Tension mode In Automatic Tension mode the system automatically adjusts the brake clutch pressure In Manual Tension mode the sys tem doesn t automatically adjust these pressures indicated by an H or L in the accumulator dis play In the Automatic Tension mode with the motor stopped setting a web force tension for either a clutch or brake loads that force into the internal computer which then automatically adjusts the air pressure sent to the clutch brake to obtain the required web tension based on the roll size When you enter the setting and then turn the motor on the indicator changes from reading the web force to the actual pressure sent to the brake to attain the required web force calculated for that roll size In Manual Tension mode the display reads actual pressure sent to the clutch brake This pres sure stays set until you change it The computer will not override your setting or change the display SPEED ACCUMULATOR DISPLAY Dis plays either the accumulator or speed d
55. otor direction arrows off and the machine in Automatic Tension mode the indicator displays the material web ten sion you set Once the motor arrow is pressed and the machine starts the computer calculates the appropriate pressure to attain the required web force based on the roll size The indicator then changes to read the actual air pressure in psi sent to the clutch brake If the machine is in Manual Tension mode the indicator reads the actual air pressure in psi sent to the clutch brake UPPER REAR BRAKE PRESSURE Adjusts the brake pressure up or down UPPER REAR BRAKE INDICATOR Indicates that this set of controls is for the upper rear brake MIDDLE REAR CLUTCH PERCENT WEB FORCE Indicates the web force tension for this clutch as a percentage of the total possible tension the clutch can exert What the pressure indicator displays changes depending upon whether the motor is on or off and what mode you are operating the machine under With the motor direction arrows off and the machine in Automatic Tension mode the indicator displays the material web ten sion you set Once the motor arrow is pressed and the machine starts the computer calculates the 10 ORCA IV Image Transfer Laminator Operation Manual appropriate pressure to attain the required web force based on the roll size The indicator then changes to read the actual air pressure in psi sent to the clutch brake If the machine is in Manual Tension mode th
56. plug the image transfer laminator and lockout power while you are performing this procedure You could be severely shocked electrocuted or get your fingers caught in the drive mechanisms 1 Remove the drive side cabinet cover using the An hex wrench by removing the screws holding the cover in place 2 Using the grease gun lubricate each grease fitting shown in Figure 4 1 with one squirt of high tem perature grease 3 Grease the main roll lift pins with high temperature grease also shown in Figure 4 1 4 Using heavy weight gear oil lubricate the lift mechanism On a yearly basis disassemble and grease all the levers and pins on the lift mecha nism Lubricate the chain using a soft cloth and gear oil Replace the cabinet covers and reconnect power to the image transfer laminator rz Note Disassembly of the laminator should be performed by a qualified service technician Maintenance and Troubleshooting Adjusting the Kick Cable Occasionally the kick cable needs adjustment to prop erly reset after use Tools required Phillips head screwdriver To adjust the kick cable 1 Remove the kick cable cover by unscrewing the four screws and lifting the cover off 2 Check the alignment of the internal mechanism It should seat squarely against the metal pin Figure 4 11 Kick Cable Incorrectly Set Mechanism Is Not Square Mechanism correctly seated against metal pin Figure 4 12 Kick
57. r 4 11 Maintenance and Troubleshooting ORCA IV Image Transfer Laminator Operation Manual Problem Number Problem Possible Cause Corrective Action 34 I pressed the shaft engage a Are the guard doors closed a Close the doors push button and the shaft did b Is the machine reset b Reset the machine See Machine not engage c Are the e stop buttons pressed Reset Procedure on page 3 3 and the kick cables reset c See problem 12 35 The machine was running a Has the machine blown a fuse a Check fuses on the back of the but stopped abruptly b Did you activate the kick cable machine b Reset the kick cable 36 The machine was running a Was the e stop pressed a Reset the e stop and reset the but then the rolls went up b Did you activate the kick cable machine See Machine Reset and the machine stopped Procedure on page 3 3 b Reset the kick cable and reset the machine See Machine Reset Procedure on page 3 3 37 Nothing seems to work a Is the machine reset a Reset the machine See Machine Reset Procedure on page 3 3 38 Slitter is not cutting a Is the blade adjusted properly a Check blade adjustment Setting b Is the blade dull or damaged the Slitter on page 3 12 c Is the bushing that mounts the b Replace blade blade worn out c Replace the bushing 39 Paper rips easily at the point Is the slitter tube enlarged a The plastic slitter tube can it
58. rds dust buildup combustible Monthly items stored too close etc e Lubricate core end plate bolts e Inspect the roll lift mechanism e Check the chain tension and lubri cate with heavy motor or gear oil Lubricate the grease fittings and Every Six chain Months Lubricate slitter collar bolts e Lubricate the roll lift mechanism e Check wire termination tightness Yearl e Disassemble the roll lift mechanism y and lubricate with lithium grease Maintenance and Troubleshooting Cleaning Tools required 80 isopropyl alcohol or dishwashing detergent e Rubber cement eraser e Several lint free paper or 100 cotton terry cloths Protective cotton gloves To clean the image transfer laminator rolls 1 Open the machine doors and gain access to the rolls A IMPORTANT Exercise extreme caution while cleaning the image transfer laminator You can be caught in the turning rolls and crushed or burned 2 While the image transfer laminator is at normal operating temperature put on cotton gloves and using a rubber cement eraser remove any heat acti vated adhesive from the rolls A IMPORTANT If silicone adhesive contacts the upper or lower roll remove it IMMEDIATELY using a rubber cement eraser It can harden within an hour and ruin the roll A IMPORTANT Do NOT pick or pull heat activated adhesive off the rolls when they are cold You can cause irreparable damage to th
59. re it to the finished product rewind For best results align one edge of the rewind core to match the material edge measurement on the unwind Web the transfer paper and tape it to the front rewind as shown in the diagram If the paper is wider than the vinyl it will be necessary to use the slitters to cut the paper down to match the width of the vinyl See Setting the Slitter on page 3 12 10 11 12 13 Operation Load and web the overlaminate as indicated in the drawing The operator has the option of lowering the pull roll now or waiting for the image to come through Check the web force for all the unwinds and rewinds and adjust as necessary Lower the main roll and start the motor Start out at a low speed 2 3 ft min 6 9 m min and then increase the speed as needed after confirming that everything is working well Check for looseness at either edge of the paper just before it enters the nip If a loose edge is detected increase the brake 2 5 psi and if the image is not yet into the nip pop the roll up and back down quickly to help pull the web straight Note Initial looseness on the edge is common It is caused by one of several things 14 15 No tension on the initial web before the roll comes down Not webbed through perfectly straight Web expansion from the heat as that stays in the nip area as the machine is webbed The roll does not come down evenly Close the door
60. ring the leveling pads by adjusting the nuts on the foot bolts 4 Move the level to the other side of the machine and level front to rear 5 Place the level directly on the chrome tie bar below the pull rolls and level the back of the machine side to side GBC Pro Tech 1998 October Installation Figure 2 8 Leveling Side to Side 6 Place the level directly on the chrome tie bar in the front of the machine and level the front of the machine side to side 7 Recheck the front to rear level condition to ensure that it has not changed If it has repeat the leveling procedure 8 Remove the four metal casters after the machine is leveled casters provided for transportation only ORCA IV Image Transfer Laminator Operation Manual Startup The first time the image transfer laminator is started and every time it is serviced you should use the follow ing checklist to confirm that the unit is operating prop erly and that all safety mechanisms are functioning Startup Checklist Start the image transfer laminator and go through the following checklist L1 Are the emergency stop buttons working Push down on one of the emergency stop buttons The image transfer laminator should stop immedi ately Reset the button by turning it clockwise until it pops up Press the reset button See Figure 1 4 Machine Reset Button to locate the main machine reset button Start the laminator The machine should resume operation
61. ritten permis sion of GBC Pro Tech GBC Pro Tech 1998 October ORCA IV Image Transfer Laminator Operation Manual Table of Contents Section 1 Safety coco a 1 1 Caution Warning Label Locations ioca bebe cds Vane Meam bie ooo 1 5 Section 2 Installation mnmmmmmnenannnennnnnannnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 2 1 Preinstallation CAGCKIISU ES ans ite e st ae aeu pete op EU UE RERUMS 2 1 WIS ACKING etait IEEE 2 4 eis H M 2 5 E CT T TU I eater eee ee ears sara ue evry 2 5 D AIDE tire sat hee At tet aa nc ERE 2 6 Section 3 Operations 3 1 cm 3 1 A 3 3 Operator Controls atan cias 3 4 EOI A o o ed ei 3 4 Front Cl tch Brake Pariel aue alias init eat ut n aeons 3 6 R arGontrol Panel As onto ete ooa A s uates tiu ac Ree ek MAU 3 8 Hear Clutch Brake Panel nt odds peace oen s 3 10 isi rU DIE 3 11 PAO IG MG Fims saien UU I TL 3 11 ASIN er ovrt ate hea ins 3 11 Recommended Materials 5 5 adasha pra open ree rice nn 3 12 Films Excluding Vinyl Transfer and Overlamination eeseeesssssesss 3 12 Vinyl Transfer and Overlamination Materials ssseeeeeeee 3 12 Setting the SST oo ite dotes ete fece que So eee ates otal edv IS RAE 3 12 Paper TIUS Den te tano bate p Dep bos Av a acte Dx dtt f 3 12 Positioning the Film and Centering the Web eee eee nenene 3
62. ro Tech s warranty does not cover malfunction of the equipment due to mishandling and or tipping GBC Pro Tech bears no responsibility for personal injury or damage due to moving the image transfer laminator improperly A WARNING Only a qualified electrician should connect power to the image transfer laminator You can be severely shocked electrocuted or cause a fire if power is improperly applied A IMPORTANT Do not operate the image transfer laminator if the power cord is damaged or frayed You can be severely shocked electrocuted or cause a fire Contact a qualified electrician to replace the cord A IMPORTANT Do not allow anything to rest on the power cord Do not locate the cord where people can walk on it You or others can be severely shocked electrocuted or cause a fire Do not open the side covers of the machine Only a qualified service technician should remove the covers You can be severely shocked electrocuted or crushed A IMPORTANT Never operate the machine with side covers open You can be severely shocked electrocuted or crushed ALWAYS USE GOOD SAFETY PRACTICES WHEN OPERATING OR SERVICING THE IMAGE TRANSFER LAMINATOR AND KNOW HOW TO REACT QUICKLY IN AN EMERGENCY Caution Warning Label Locations On your ORCA IV Image Transfer Laminator are important safety labels See Figure 1 5 Locations of Safety Labels for the location o
63. ro Tech 1998 October Safety ORCA IV Image Transfer Laminator Operation Manual The machine is equipped with four emergency stop buttons located on either side of the front and back of the image transfer laminator Any of these if engaged stops the machine To continue operation all emer FRONT 72 gency stop buttons must be in the out position and you A must perform the Machine Reset Procedure See Machine Reset Procedure on page 1 3 Push any button Twist each button A to stop the to resume laminator operation the button pops out A a Emergency Stop Kick Cable Figure 1 1 Using the Emergency Stop Buttons In addition the ORCA IV is equipped with two emer gency stop kick cables located at the lower front and back of the image transfer laminator Emergency Stop Kick Cable Figure 1 2 Using the Emergency Stop Kick Cables Either of these if stepped on or kicked stops the lami nator and raises the rolls To continue operation press the kick cable reset button Then complete the Machine Reset Procedure See Machine Reset Procedure on page 1 3 1 2 GBC Pro Tech 1998 October ORCA IV Image Transfer Laminator Operation Manual Kick Cable Reset Button Figure 1 3 Kick Cable Reset Button Machine Reset Procedure Perform this procedure whenever an emergency stop button or
64. ront Brake E Percent Web Force Brake Indicator Unwind Rewind Shaft 101 gt 12 Lower Front Brake Locking System ON OFF Pressure Lowerr Front Brake 1 7 a is Lower Front Brake Percent Braking Indicator Force Figure 3 6 Front Brake Panel UPPER MIDDLE CLUTCH REWIND PER CENT WEB FORCE Indicates the web force tension for this clutch as a percentage of the total possible tension the clutch can exert What the pressure indicator displays will change depending upon whether the motor is on or off and what mode you are operating the machine under With the motor direction arrows off and the machine in Automatic Tension mode the indicator displays the material web tension you set Once the motor arrow is pressed and the machine starts the com puter calculates the appropriate pressure to attain the reguired web force based on the roll size The indicator then changes to read the actual air pres sure in psi sent to the clutch brake If the machine is in Manual Tension mode the indicator reads the actual air pressure in psi sent to the clutch brake UPPER MIDDLE CLUTCH REWIND PRES SURE Adjusts the clutch pressure up or down UPPER MIDDLE CLUTCH REWIND INDI CATOR Indicates that this set of controls is for the upper middle clutch UPPER FRONT CLUTCH REWIND PER CENT WEB FORCE Indicates the web force tension for this clutch as a percentage of the total possible tension the clutch c
65. s and increase the speed as required Observe the machine as it runs the material Pay close attention to the web Look for loose webs or spliced rolls and check the image quality A IMPORTANT When the process is complete stop the machine and raise the roll Do not let either paper or vinyl run through the nip alone The vinyl could stick to the roll and the transfer paper would transfer to the bottom roll resulting in a large clean up job GBC Pro Tech 1998 October 3 13 Operation Film Spacing ORCA IV Image Transfer Laminator Operation Manual Table 3 2 Film Spacing Distance From Distance From Film Size End of Shaft Machine Side to Material to Material Side Plate Side Plate 54 7 15 16 7 1 2 137 16 cm 20 16 cm 19 05 cm 49 10 7 16 10 124 46 cm 26 51 cm 25 40 cm 48 10 15 16 10 1 2 121 92 cm 27 78 cm 26 67 cm rz Note Always set the drive side and keep it set as the base When changing film remove the end plate on the con trol side of the shaft The new roll should then be pushed tight up to the plate on the drive side and the shaft should be slid over and engaged in the drive Operational Tips and Tricks Suggested leaders e For vinyl 65 165 1 cm e For paper 75 190 5 cm To advance the paper without the vinyl You may want to advance the paper without the vinyl for several reasons e At the beginning of a new roll to clear th
66. such a manner that another worker can start the machine while you are working on or within the machine Never change or defeat the function of electrical interlocks or other machine shutdown switches Before starting this machine check that All persons are clear of the machine No maintenance work is being performed on the machine All guards are in place All parent rolls are well chucked in the unwind stands The machine is free of paper scraps wraps and jams There is a potential hazard of entanglement in this machine caused by items such as long hair loose clothing and jewelry Make sure your clothing and hair fit closely to your body and that all jewelry rings and watches are removed CAUTION Air pressure must be less than 100 PSI 700 kPa to avoid damaging the machine WARNING EMERGENCY STOP BUTTON Press this button to stop the machine cycle remove electric power and separate open rolls to eliminate a pinch point on some machines Electric power disconnect and lock out location CAUTION EXPOSED ROLLER Can cause personal injury Keep hands long hair ties jewelry and loose clothing away from this area Emergency Stop Kick Cables Located Below Kick or Step on to Stop Laminating Process SEE INSTALLATION INSTRUCTIONS BEFORE CONNECTING TO THE SUPPLY HIGH LEAKAGE CURRENT Earth connection essential before connecting supply Earth ground GBC Pro Tech 1998 October Safety ORCA IV Im
67. to the buyer Please review your insurance cov erage prior to shipment as you are responsible for all subsequent freight charges and risks Before signing the Bill of Lading you should be sure to inspect the machine for signs of damage or missing items if appli cable you should make a note of this on the Bill of Lad ing The ORCA IV Image Transfer Laminator is shipped encased in shrink wrap via Air Ride Van To unpack the machine 7 Have the image transfer laminator rolled off the Air Ride Van and placed on the floor by licensed riggers A IMPORTANT ORCA IV Image Transfer Laminator Operation Manual 8 Gently unwrap the shrink wrap from around the image transfer laminator and remove the foam pro tecting the corners of the machine A IMPORTANT Do not use a knife or other sharp instrument during installation or while servicing the image transfer laminator You can cause irreparable damage to the rolls Do not attempt to move the image transfer laminator across anything other than a flat level surface without trained and qualified riggers You can be crushed or seriously injured The ORCA IV Image Transfer Laminator is a large and heavy piece of equipment It is necessary to employ LICENSED RIGGERS ONLY to move the machine The image transfer laminator is not designed to be tipped up or sideways in any way Such action disturbs the exact alignment of the rolling parts of the machine and requires extensive
68. tomatic Tension mode the indicator displays the material web ten sion you set Once the motor arrow is pressed and the machine starts the computer calculates the appropriate pressure to attain the required web force based on the roll size The indicator then changes to read the actual air pressure in psi sent to the clutch brake If the machine is in Manual Tension mode the indicator reads the actual air pressure in psi sent to the clutch brake LOWER FRONT BRAKE PRESSURE Adjusts the brake pressure up or down LOWER FRONT BRAKE INDICATOR Indi cates that this set of controls is for the lower front brake Operation GBC Pro Tech 1998 October Operation Rear Control Panel BE Pull Roll Torque o Q amp oworr 0 27 g Roll Pull Force 7 Adjustment Display Pull Roi Pressure Display Main Roll gt g Pull Roll UP DOWN UP DOWN Vig 3 10 Pull ron xi e v Roll Torque Pressure A Adjustment Adjustment CON pL Cooling Fan 2 ON OFF GBC Logo Lp Automatic Manual Mode Control pe 12 Accumulator Z Reset Speed CJ Ss Accumulator mal Speed Display Accumulator BL L Y N 23 Toggle Speed B gt lt 1 motion Control Adjustment FORWARD STOP REVERSE Figure 3 7 Rear Control Panel PULL ROLL PRESSURE DISPLAY Displays the air pressure pushing the upper pull roll down MAIN ROLL UP DOWN Sets the upper main roll to the up load or
69. ttain the required web force based on the roll size The indicator then changes to read the actual air pressure in psi sent to the clutch brake If the machine is in Manual Tension mode the indicator reads the actual air pressure in psi sent to the clutch brake MIDDLE FRONT BRAKE PRESSURE Adjusts the brake pressure up or down MIDDLE FRONT BRAKE INDICATOR Indi cates that this set of controls is for the middle front brake UNWIND REWIND SHAFT LOCKING SYS TEM ON OFF Engages disengages the unwind rewind shaft locking system The switch disen gages the locking system with the door either open or closed with the motor off The doors must be shut to engage the system If the doors are shut and the unwind rewind shafts are disengaged pushing the motion control engages them automatically Note the color coding on each shaft and the shaft loading tray Unwinds are marked with blue and rewinds are marked with red Always use the cor rect shaft in each loading position GBC Pro Tech 1998 October ORCA IV Image Transfer Laminator Operation Manual 11 12 13 LOWER FRONT BRAKE PERCENT BRAK ING FORCE Indicates the web force tension for this brake as a percentage of the total possible tension the brake can exert What the pressure indi cator displays changes depending upon whether the motor is on or off and what mode you are operating the machine under With the motor direction arrows off and the machine in Au
70. ty of others is important to GBC Pro Tech This section contains important safety information The following symbols are used throughout this man ual to indicate warnings and cautions A DANGER Indicates an imminently hazardous situation which if not avoided will result in death or serious injury WARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury A CAUTION Indicates a potentially hazardous situation which if not avoided could result in minor or moderate injury or alerts against unsafe practices or alerts against actions which could damage the product A IMPORTANT Indicates important additional information The ORCA IV Image Transfer Laminator has been designed with safety as a primary consideration How ever you must become thoroughly familiar with the controls proper operation proper service procedures and safety features of the image transfer laminator before using or servicing the unit Safety The GBC Pro Tech ORCA IV is a powerful machine that is designed for vinyl transfer and over lamination The forces required to accomplish these tasks are very large The air cylinder system used to provide downward pressure on the top roll is capable of producing forces greater than 1000 pounds 454kg This force is applied to any object presented in the opening called the nip between the two

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