GBC 80-99 User's Manual
Contents
1. 5 7 Process control chart blank 1 5 10 Process control diagram blank 5 11 Hot mount Chart 2 2 5 12 Hot mount Diagram 2 2 ssicasscasssecesesavncesosssecesesovacesacasecssesereansusas 5 13 Hot mount Laminate Chart 2 3 eere 5 14 Hot mount Laminate Diagram 2 3 ccccssssssssssscccsssssssssseees 5 15 Page II GBC Pro Tech June 2000 Orca 80 99 Operation and Maintenance Manual Table of Contents Encapsulation Chart 2 4 sssccsiscsccsscssossonscsssscsseovsooassescssscsssdeensevece 5 16 Encapsulation Diagram 2 4 5 17 Hot laminate PSA mount Chart 2 5 1 1 114 4 5 18 Hot laminate PSA mount Diagram 2 5 e eee 5 19 Hot laminate PSA mount Second pass Chart 2 6 5 20 Hot laminate PSA mount Second pass Diagram 2 6 5 21 Cold overlaminate PSA mount Chart 2 7 5 22 Cold overlaminate PSA mount Diagram 2 7 5 23 Cold overlaminate PSA mount Second pass Chart 2 8 5 24 Cold overlaminate PSA mount Second pass Diagram 2 8 5 25 Cold laminate only using a sled Chart 2 92. ON m BOTTOM COOLING 5 PULL ROLLER CLUTCH OFF 7 ON PRESSURE SCH CONTROL F BOTTOM FAN BANK ON OFF AIR PRESSURE ADJUSTMENT PULL ROLL CLUTCH ON OFF AIR PRESSURE ADJUSTMENT putt ROLL UP DOWN AIR PRESSURE GAUGE orr ADJUSTMENT 1 BOTTOM BRAKE BOTTOM REWIND BOTTOM BRAKE ON OFF TENSION PRESSURE GAUGE PR AIR PRESSURE ADJUSTMENT GER BOTTOM CLUTCH BOTTOM CLUTCH ON OFF O Fig 2 2 REAR CONTROL PANEL GBC Films Group June 2000 Page 5 3 Operations Orca 80 99 Operation and Maintenance Manual Operator Controls The operator controls for the Orca laminator are operator position See Figures 2 1 and 2 2 The names and functions of these controls are as follows FRONT CONTROL PANEL Please note that in each of the control sections there is a Pressure Gauge an On Off switch and an Air Pressure Regulator The Pressure Gauge shows the operational pressure The On Off switch turns the control function on or off The Air Pressure Regulator adjusts the air pressure for the control function A TOP BRAKE CONTROLS Regulation of the upper unwind shaft brakes B TOP CLUTCH CONTROLS Front upper rewind shaft clutch regulation C L
3. 5 26 Cold laminate only using a sled Diagram 2 9 5 27 O GBC Pro Tech June 2000 Page III Table of Contents Orca 80 99 Operation and Maintenance Manual Section 6 Maintenence pec RUNG 6 1 IVIOIH DIS ioo toss ety es de inv Cab vov De QU YE Dr DeL Ree Dri evt eie uri 6 1 SIX 5 6 2 6 3 GBC Pro Tech June 2000 Orca 80 99 Operation and Maintenance Manual Safety SAFETY READ THIS SECTION BEFORE OPERATING THE ORCA 80 99 LAMINATOR FOR YOUR SAFETY Your safety as well as the safety of others is important to GBC Pro Tech In this instruction and on the product are important safety messages Read these messages carefully 1 Read all these instructions 2 Save these instructions for later use 3 Follow all warning and instructions marked on the product 4 Unplug this product from the wall outlet before cleaning Do not use liquid cleaners or aerosol cleaners Use a damp cloth for cleaning 5 Do not use this product near water 6 This product should be operated from the type of power source indicated on the marking label If you are not sure of the type of power available consult your dealer or a qualified and certified electrician 7 Do not allow anything to rest on the power cord Do not locate this product where persons will walk on the cord 8 Never push objects of any kind in
4. ORCA 80 99 OPERATION amp MAINTENANCE MANUAL June 2000 GBC Pro Tech Do not duplicate without written permission GBC Pro Tech 4151 Anderson Road DeForest WI 53532 Ph 608 246 8844 Revision Fx 608 246 8645 Part number 930 055 Orca 80 99 Operation and Maintenance Manual Table of Contents Table of Contents Section 1 Safety 1 1 Section 2 Warranty Limited warranty information 1 eee eee e 2 1 Exclusions to 2 5 6 otro ovx 2 1 Section 3 Specifications Section 4 Installation 5 M 4 1 Dia eran weiss ER 4 2 Electrical Requirements ecce eee eee eene eee eee e eese 4 3 Suggested Lay Oul E YR oV Mg DUAE 4 4 Air Requirements 4 5 GBC Pro Tech June 2000 Page I Table of Contents Orca 80 99 Operation and Maintenance Manual Section 5 Operations cgi m 5 1 Front control panel diagram eee eere eee eerte nnne 5 2 Rear control panel diagram ecce eee e eee eee eee eren nnne 5 3 Front control panel 5 4 Rear control ees 5 4 5 5 PEOCOSSPS
5. RECYCLING INSTRUCTIONS The crate components can be reused for shipping the machine again or may be disassembled and the wood and screws recycled The shrink wrap however is not recyclable so therefore must be discarded In order to begin operation of the machine the Up Down rates for the main and pull rolls and the nips must be set see the Operation section of this manual Once set the machine is ready for operation GBC Films Group June 2000 Page 4 5 Orca 80 99 Operation and Maintenance Manual Operations OPERATION Safety Safety is always the primary concern If you have not read the safety information at the front of this manual do so now Do not attempt operation of the machine until you fully understand this safety information General Precautions 1 Keep razor blades knives and all other sharp objects away from the chrome and silicone rollers They are easily damaged and very expensive to replace CAUTION Insert shims to keep the laminating and pull rolls apart when the machine is not in use Do not rely on the air supply Prolonged contact can damage the rolls 2 Harsh chemicals such as Toluene or MEK will destroy the silicone covering on the laminating rolls The rolls should be cleaned daily following the procedure outlined in the Maintenance section of this manual CAUTION If silicone adhesives contact the top or bottom roll remove it IMMEDIATELY using isopropyl alcohol It
6. ON OFF Bottom Heater Controller Controls whether or not the bottom heater controller is on or off E BOTTOM HEATER CONTROLLER Controls the lower main roll s operational temperature and provides a readout of the actual temperature F ON OFF Bottom Fan Bank Controls whether or not the bottom fan bank is on or off G PULL ROLLER CLUTCH CONTROLS Regulation for the bottom pull roller clutch CAUTION Use the minimum laminator roll pressure consistent with good results Excess pressure can damage the laminating rollers Page 5 4 GBC Films Group June 2000 Orca 80 99 Operation and Maintenance Manual Operations H PULL ROLLER PRESSURE CONTROLS Regulation for the upper pull roll pressure and up down I BOTTOM BRAKE CONTROL Regulation for the bottom rear unwind brake J BOTTOM CLUTCH CONTROL Regulation for the bottom rear rewind shaft s clutch Setup Set up of the Orca laminator is quick and straightforward when instructions are followed directly When you first receive the Orca Laminator the nips must be set before operation The procedures for setting the main and pull roll nips are on pages 8 1 and 8 2 Laminator Roll Pressure 1 You should use only the minimum amount of roll pressure needed to accomplish the task While higher nip pressure can make the adhesive bond faster excess pressure can damage the rollers Wrinkles bubbles and such have causes that generally cannot be
7. it is also helpful to have a table the same height as the pull roller nip to help feed the board and image into the pull rollers Page 5 20 GBC Films Group June 2000 Orca 80 99 Operation and Maintenance Manual Operations RELEASE LINER Chart 2 6B TWO PASS HOT OVERLAMINATE WITH PRESSURE SENSITIVE MOUNT ADHESIVE SECOND PASS GBC Films Group June 2000 Page 5 21 Operations Orca 80 99 Operation and Maintenance Manual PROCESS CONTROL CHART 2 7 Process Cold overlaminate with pressure sensitive mount adhesive Materials top bottom PSA Laminate PSA Mount Adhesive Front Control Panel Rear Control Panel Adjustments Adjustments Laminator Roller ON 40 p s i Bottom Brake front 20 p s i Top Brake Top Clutch Bottom Clutch front OFF Forward Reverse FORWARD Laminator Roller Shims 0 Helpful Hints Notes Page 5 22 GBC Films Group June 2000 Orca 80 99 Operation and Maintenance Manual Operations UNWIND RELEASE PAPER REW IND ES MOUNT ADHESIVE UNWIND Chart 2 7B TWO PASS COLD OVERLAMINATE WITH PRESSURE SENSITIVE MOUNT ADHESIVE FIRST PASS GBC Films Group June 2000 Page 5 23 Operations Orca 80 99 Operation and Maintenance Manual PROCESS CONTROL CHART 2 8 Process Cold overlaminate with pressure sensitive mount adhesive Second pass Materials top bottom 3 16 Foamcore Front Control Panel Rear Control Panel Adjus
8. alcohol and a 100 percent cotton terry rag Samples of these two items were supplied in the accessory kit shipped with the machine Monthly Setting the Nip The gap between the two laminator rolls and the secondary drive rollers is called the nip or roll nip It should be checked once a month They should be adjusted according to the following procedures Main Roll Nip Setting Procedure 1 Make sure that the machine has both power and air It is also necessary to make sure that the up down rates of the upper main roll are even prior to setting the nip if not follow the rate adjusting procedure on page 4 2 Please note that the main rolls have to be cold room temperature when performing this procedure 2 Remove the shims and set the main roll pressure to 40 psi Note that this must be done with the upper main roll in its fully up position 3 Loosen main roll air cylinder caps and spin them to their fully up position 4 Lower the upper main roll and spin down the main roll air cylinder caps until they are finger tight and secure 5 Raise the upper main roll The main roll nip is now set Pull Roll Nip Setting Procedure 1 Make sure that the machine has both power and air and that both cabinets are open It is also necessary to make sure that the up down rates of the upper pull roll are even prior to setting the nip if not follow the rate adjusting procedure on the adjacent column 2 Remove the shims and set t
9. cured with more pressure 2 A typical roll pressure for soft substrates such as Foamcore or Orca Board is between 20 to 30 pounds per square inch PSI or 32 to 205 kPa 3 The range of typical values for hard substrates is 25 to 50 PSI 170 to 345 kPa Loading the Film Filmis loaded on the appropriate unwinds Instructions later in this section will cover loading and aligning film For applications such as encapsulation film will be fed from both top and bottom unwinds process of loading and aligning film is the same for both the top and the bottom There are two important points to remember when loadingfilm CAUTION Assure that film is always mounted so that the adhesive side will face outward from the laminating roller 1 The adhesive side of the film must be oriented away on the outside of the laminating roller Otherwise it will immediately bond to the roller creating a major clean up project Films have a shiny side and a dull side The dull side is the one with the adhesive Thus the dull side should ALWAYS face outward from the laminating roll 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 excess glue on rolls and other assorted troubles will result CAUTION Unless the two films fed to the nip are carefully aligned poor results will be seen Positioning Film The foll
10. free from defects in material and workmanship for a period of one 1 year from the date of delivery to the customer This warranty is the only warranty made by Pro Tech and can not 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 product 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 modification incorrect line voltage contaminated air supply or by fire accident or flood or other hazard This warranty specifically does not cover damage to the laminating rollers caused by knives razor blades other sharp objects failure caused by adhesives or improper use of the machine Warranty repair or replacement does not extend the warranty beyond the initial one year period from the date of delivery THE WARRANTY MADE HEREIN IS IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING ANY WARRANTY OR MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE GBC PRO TECH WILL NOT BE LIABLE FOR PROPERTY DAMAGE OR PERSONAL 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 EQUIPME
11. is the same for top and bottom 1 Set the heater switch to ON 2 Adjust the temperature controller for the desired operating temperature using the controller push bottoms For the Syrlec type controller use the up and down arrows to adjust the set point Hold down the desired arrow until the correct set point is achieved For the CAL3200 it is necessary to press the button at the same time as the up or down arrow to adjust the set point temperature 3 When heating the rolls keep the top roll down and turning at a moderate speed to prevent uneven heating 4 It will take approximately 25 minutes for the laminating roller s to reach operating temperature When the pre set operating temperature has been reached the machine is ready to use Cooling with optional cooling fans The following procedure is the fastest way to cool down the machine Natural cooling can also be employed 1 Set the heater switches to OFF 2 Position the two rear fan banks so that they are tilted to direct air flow at the rolls 3 Set the Laminator Roll Control to the DOWN position 4 Set the Forward Reverse switch to the FORWARD position 5 Set the speed control to 5 fpm 150 cpm 6 Let the machine run until the laminating rolls return to room temperature Paper Tips 1 Always cut the leading edge of a print straight so they can be fed perpendicular to the laminating rolls Process Control Charts Chart 2 1 and 2
12. operator safety as a primary consideration However operators must become thoroughly familiar with the controls and proper operation and safety features of the machine before starting to use the unit O GBC Films Group June 2000 1 1 Safety Orca 80 99 Operation and Maintenance Manual GBC Pro Tech laminators are powerful machines which are designed to accomplish specific tasks such as mounting laminating and encapsulating The forces required to accomplish laminating can vary from negligible to very large The air cylinder system used to provide downward pressure on the top roll is capable of producing forces greater than 1000 pounds 454 kg This force can be applied to any object that may be present in the opening called the nip between the two rollers As a safety measure the laminator is equipped with a photoelectric eye system which stops the machine when objects or hands are located in the nip area Once the blocking object is removed and the light beam is reestablished the laminator rolls resume turning Operators should use care in lowering the top laminating roll and know how to react quickly in an emergency The laminator roll UP DOWN switch is located on the front instrument panel labeled Laminator Roll Controls on the left hand side of the machine As the name implies this switch controls the up and down motion of the top laminator roll Before turning this switch to the DOWN position assure
13. pressure sensitive materials 0 80 0 cm wide with films 3 7 6 cm ID core Laminating Speeds 0 to 30 fpm 0 to 9 Mpm with variable speed reversible action START and STOP controlled via the front instrument panel switch or with a foot switch Unwind Rewind Three unwind positions three rewind positions Safety Features 1 Photo eye motor stop 4 emergency stop buttons and two kick cables to stop the machine and raise rolls Warranty One year parts warranty except silicone roll coverings and table tops Electric 220 VAC 50 or 60 Hz single phase 60 65 Amps Three phase 32 Amps Europe only Compressed Air 2 CFM 100 PSI GBC Films Group June 2000 Page3 1 Orca 80 99 Operation and Maintenance Manual Installation INSTALLATION Uncrating the Machine CAUTION When taking the top off care should be taken so that the top does not fall into the crate possibly damaging the laminator It might be necessary to use two or three people for this task During the uncrating process make sure that the screws do not end up on the floor They can cause problems later when trying to roll the machine into position To uncrate the Orca 80 99 Laminator you will need a phillips head screwdriver It helps to have a cordless drill with the screwdriver bit because there are quite a few screws to remove throughout this procedure In order to minimize the possibility of damage to your ne
14. the machine on its four comers and carefully rolling the machine off the crate bottom see diagram The machine can now be rolled into its final operating position Choose a spot with sufficient space around the unit so that there can be front and back work tables and adequate space for efficient material flow Thus a typical room area requirement for the ORCA 80 99 is 20 X 24 feet 6 0 x 7 3 Meters to allow use of work tables in front and to the rear of the machine See the suggested layout in Fig 1 1 page 4 4 Once the Orca 80 99 Laminator has been placed in its final position optimum performance is obtained by installing the supplied leveling pads and leveling the machine Install one leveling pad on each foot bolt tightening securely Lower the leveling pad to the floor by turning down the foot bolts Turn all the bolts sufficiently to lift all four of the casters off the floor CAUTION Some generation of static electricity is unavoidable during the laminating process due to the nature of the materials used In order to avoid any hazard of ignition fire or explosion due to static spark it is imperative that the operating environment is free of dust flammable liquids and vapors Then face the machine and place a carpenter s level left to right on one of theidlers Adjust the bolts on the front two foot brackets so that the machine is level left to right Then move the level to the rear of the machine and adjust th
15. 1B show a blank set of process control charts for the ORCA 80 These charts are where you record the way you thread film through the machine s rolls and idlers called webbing and the setting of controls and switches for each product and process GBC Pro Tech laminators respond in a very accurate and repeatable manner The charts provide a way to set up each time every time for repeatable performance by assuring all controls are set to optimum Page 5 6 GBC Films Group June 2000 Orca 80 99 Operation and Maintenance Manual Operations The process charts are also an excellent tool for training new operators They provide a road map for correct machine setup and operation The process control charts should be kept in this manual or in a book close to the Orca Use the machine to encapsulate the popular charts so they can withstand coffee spills and will be available for ready reference In the rest of this section you will find completed process control charts for the basic operations of the machine These are based on Orca Film and Orca Board and typical prints If you have a special application use the blank charts to make your own records Information When trying new products and processes remember that GBC Pro Tech s customer service technicians are only a phone call away Mounting Only 1 Setup A See process chart 2 2 and 2 2B B Set Shims C Upper Laminator Roll Pressure 40 to 80
16. A Prepare to put the print through a second time to mount the print to the substrate anything from wood to Masonite to Gator foam Start by setting the shims to the appropriate spacing for the material used B Trim the board to the size of the print C Align the work to the board and assure an exact fit Place weights on the center of the print to assure that it does not move relative to the board during the next steps D Raise one end of the print and peel back approximately two inches of the liner to expose the adhesive that was applied to the print in pass 1 Fold it under Lay the print back down evenly and extremely flat From the center outward tack the exposed adhesive to the substrate E Position the piece so that the end with the liner peeled back is facing the nip Insert the first one inch of the board into the nip F Very carefully wrap the print back and over the top laminating roll Be sure there are no wrinkles in the nip area Carefully peel off the liner as the board progresses through the laminator G Trim the piece to the finished size Hot Mount Laminate A Refer to charts 2 7 2 7B 2 8 and 2 8B B Encapsulate image see chart 2 7 Page 5 8 GBC Films Group June 2000 Orca 80 99 Operation and Maintenance Manual Operations C Raise Main Roll Hot D Reverse Motor E 2nd Pass Set Nip Height and tack leading edge Run through as liner is being pulled off Cold Overlamina
17. AMINATOR ROLL CONTROLS Regulation of the main laminating rolls D BOTTOM BRAKE CONTROLS Regulation of the front lower unwind brake E BOTTOM CLUTCH CONTROLS Regulation of the shaft s lower front rewind clutch RUN JOG SWITCH Changes control of the machine drive from a foot switch operation to continuous run It also allows the operator to Jog the rolls for a short period of time G REV FWD This switch controls the direction of the drive system forward or reverse H SPEED CONTROL Adjusts the speed of the machine from zero to maximum as the control is turned clockwise I SPEED READOUT Digital readout of the machine speed and total throughput in either metric or standard units J ON OFF LAMP Top Heater Denotes whether the top heater controller is on or off K ON OFF LAMP Bottom Heater Denotes whether the bottom heater controller is on or off L PHOTO EYE LAMP Denotes whether or not the PHOTO EYE is blocked M MAIN POWER LAMP Denotes whether or not the main power is on the machine N MAIN POWER SWITCH Turns the main power on and off REAR CONTROL PANEL A ON OFF Top Heater Controller Controls whether or not the top heater controller is on or off B TOP HEATER CONTROLLER Controls the upper main roll s operational temperature and provides a readout of the actual temperature C ON OFF Top Fan Bank Controls whether or not the top fan bank is on or off D
18. NT Exclusions to the Warranty This warranty specifically does not cover 1 Damage to the laminating rollers 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 3 Improper use of the machine GBC Films Group June 2000 Page 2 1 Orca 80 99 Operation and Maintenance Manual Specifications ORCA 80 99 SPECIFICATIONS Description Floor standing laminator with multiple unwind positions for high productivity heat activated laminating encapsulating heat transfer and mounting The laminator can also be used with pressure sensitive films for cold mounting and laminating applications Includes Outfeed edge slitters for in line trimming of finished product Dimensions L 120 D 50 H 66 L 3M D 1 27M H 1 68M Weight uncrated 2800 pounds 1270 kg Laminating Rolls 86 5 length 220 cm roll face with thermally conductive silicone covered with high release silicone surface upper and lower rolls internally heated Temperature controlled by state of the art infrared sensors with closed loop digital control systems independently adjustable for both top and bottom rolls Laminating Opening 1_ 4 75 cm maximum opening controlled with dual air cylinders Laminating Material Uses heat activated 0 74 and
19. PSI 275 550 kPa D Speed 3 E Upper Laminator Roll Heat 245 degrees F 118 degrees C Mounting Only continued 2 Procedure A Lay the print on the board Using a tack iron tack the leading edge of the print down onto the board so it is held in place B Put a piece of contact release paper over the print Otherwise adhesive will be applied to the laminating roller which can cause damage and the ink from electrostatic prints will be deposited on the roll C Feed the print Orca board package though the nip Mounting Laminating The following procedure is for one step mounting and heat activated laminating using mounting board with one adhesive side such as Orca Board 1 Setup A The setup is shown in process chart 2 3 and 2 3B B Mount the film and web as shown in chart 2 3B C Shims Set the two front shim dials to 1 32 less than board height D Laminator Roll Pressure 40 PSI 275 kPa E Speed 3 fpm 90 cpm F Upper Laminator Roll Heat 245 degrees F 118 degrees C G Cooling Off H Film Roll Brake Pressure 20 PSI 135 kPa 2 Procedure A Feed the Orca board dull adhesive side up with the print positioned as desired A tack iron may be used to hold the leading edge of the print in place Encapsulation 1 Setup A Refer to process chart 2 4 and 2 4B for webbing instructions GBC Films Group June 2000 Page 5 7 Operations Orca 80 99 Operation and Maintenance Ma
20. and the slots that both the upper main and pull rolls slide up and down in Complete the lubrication by wiping the entire length of the chain with an oily rag Itis also important to note that over lubrication of bearings is a leading cause of bearing failure Close the side panels and reconnect the electrical power and air supply As Needed Chain Tensioning 1 Make sure that the machine has air only no power and that the right drive side cabinet is open see the diagram on page 8 3 2 Using a large adjustable wrench turn the appropriate chain tensioner until the desired chain tension is achieved Make sure that the chain tension of each of the three chains is fairly close If notit might cause stuttering in the feed of the laminator Page 6 2 O GBC Films Group June 2000 Maintenance Orca 80 99 Operation and Maintenance Manual SECONDARY gt lt D o CO OR M CHAIN 3 CHAIN TENSIONERS CHAIN 4 CHAIN TENSION DIAGRAM Page 6 GBC Films Group June 2000
21. cess at the end of a sheet due to curl up of the sheet end Operators are cautioned to use the foot switch for as short a time as practicable and to exercise caution when doing so O GBC Films Group June 2000 Page5 1 Operations Orca 80 99 Operation and Maintenance Manual UNWINDS 3 ON OFF AIR PRESSURE Mn nae ADJUSTMENT TOP BRAKE REWIND TOP BRAKE CONTROLS Ss ON OFF LAMINATOR ROLL TOP CLUTCH CONTROLS AIR PRESSURE aum UP DOWN GAUGE D BOTTOM UNWIND LAMINATOR ROLL CONTROLS m ON OFF o o TOP HEATER SWITCH G BOTTOM BRAKE CONTROLS SCH REWIND ON OFF ON OFF LAMP RUN JOG SWITCH BOTTOM HEATER SWITCH ON OFF LAMP SCH FORWARD REVERSE SWITCH PHOTOEYE 1 LAMP MAIN POWER SPEED CONTROL WER OTOR CONTROLS ON OFF om iio LAMP MAIN POWER 1 SPEED READOUT SWITCH Fig 2 1 FRONT CONTROL PANEL Page 5 2 GBC Films Group June 2000 Orca 80 99 Operation and Maintenance Manual Operations TOP ON OFF TOP HEATER B CONTROL TOP FAN BANK C ON OFF PULL ROLL CLUTCH PRESSURE GAUGE PULL ROLL PRESSURE GAUGE BOTTOM UNWIND TENSION PRESSURE OFF ON COOLING FANS OFF ON
22. ckness as the board being mounted to While maintaining paper tension lay the image to be mounted on the board and follow the leader board into the nip Page 5 14 GBC Films Group June 2000 Orca 80 99 Operation and Maintenance Manual Operations IMAGE CHART 2 3B ONE PASS HOT MOUNT AND LAMINATE GBC Films Group June 2000 Page 5 15 Operations PROCESS CONTROL CHART 2 4 Process Encapsulation Orca 80 99 Operation and Maintenance Manual Materials top bottom 3 mil Gloss 3mil Gloss Front Control Panel Adjustments Top Brake Top Clutch Laminator Roller Bottom Brake front Bottom Clutch front Forward Reverse Speed Laminator Roller Shims Helpful Hints Notes Page 5 16 ON 20 p s i ON 20 p s i ON 60 p s i N 20 p s i OFF FORWARD 4 6f p m 0 Rear Control Panel Adjustments Top Heat Bottom Heat Top Cooling Fans Bottom Cooling Fans Pull Roller Clutch Pull Roller Pressure Bottom Brake rear Bottom Clutch rear Pull Roller Shims O GBC Films Group June 2000 ON 230 F 110 C ON 230 F 110 C ON ON ON 80 p s i ON 60 p s i OFF NA OFF NA Orca 80 99 Operation and Maintenance Manual Operations UNWIND Chart 2 4B ENCAPSULATION GBC Films Group June 2000 Page 5 17 Operations Orca 80 99 Operation and Maintenance Manual PROCESS CONTROL CHART 2 5 Process Hot Overlaminate with Pre
23. dry Moisture will cause corrosion and particles can block pneumatic controls Either can cause the laminator to malfunction It is the customer s responsibility to provide appropriate filters and water traps for the air line before the air is routed to the laminator GBC Pro Tech suggests that the best approach to the air requirement is to provide a dedicated small compressor for the laminator A standard light duty 1 2 to 3 4 horsepower 1 kW electric air compressor with 1 5 to 2 5 CFM output with a 2 5 gallon 20 Liter storage tank is appropriate Air is fed to the machine via a 1 4 inch quick disconnect male connector This connector is located below the cabinet on the left side of the machine Once the air supply and electrical power are connected to the machine proceed to the section on Operation in this manual 9 Next remove the paper coverings from the roll After the roll coverings have been removed you will need to open the accessory pack The accessory pack contains Qty Description Set Allen wrenches Slitting knife Manual Bottle of Isopropyl Alcohol 100 white cotton terry rags Set spare fuses eS Se eS eS Additional slitter knives T handle wrench 5 16 T handle wrench 1 4 Masking Tape Tape Measure Rubber Cement Pick Up Shim Set Leveling Pads Outfeed Slitters O Rings Brake Oil Air Tool N N BRR RR kK kK N These items are needed to put the machine into operation
24. e rear two leveling pads Next place the level front to rear on one of the air cylinder brackets and adjust the bolts equally on the two foot brackets on that side Move the level to the other air cylinder bracket and repeat the procedure for the other side After both sides have been leveled front to back go back and check the side to side level condition of the front and rear of the machine to insure that it has not changed If it has repeat the procedure until the machine s front rear and both sides are all level Tighten the lock nuts securely to the foot brackets 8 Atthis point a qualified electrician connects power to the machine Make sure before supply poweris provided that the machine circuit breaker is in the off position This is also the point where the appropriate supply of clean dry compressed airis connected to the machine see power and air requirements Electrical Requirements The ORCA 80 99 is designed to accept 220 to 240 volt AC 50 60 Hz 60 Amps single phase 3 wire USA The peak power required by the unit is 55 Amperes Or in Europe only 3 N phase 230 400 VAC 50 Hz 25 Amps per phase Before attempting to electrically connect or operate your new Orca 80 99 Laminator a qualified licensed electrician should be consulted to ensure that an adequate power supply having the appropriate capacity overcurrent protection safety lockouts etc is available and to ensure that the power supply of the O
25. he pull roll pressure to 40 psi The upper pull roll should be in the fully up position when making these adjustments GBC Films Group June 2000 Page 6 1 Maintenance Orca 80 99 Operation and Maintenance Manual 3 Loosen both pull roll air cylinder caps and spin them to their fully up position 4 Lower the upper pull roll and spin down the pull roll air cylinder caps until they are finger tight and secure them The pull roll nip is now set Cylinder Up Down Rate Adjustment If the upper laminating roll or upper pull roll moves up or down unevenly the cylinder flow controls need to be adjusted Turn them clockwise to slow the up down rate and counter clockwise to increase the up down rate To correct for uneven motion when the roll is going up adjust the flow controls at the top of the air cylinders To adjust for uneven lowering set the air pressure on the laminating roll regulator at 100 pounds per square inch PSI 690 kPa and make the necessary adjustments to the flow controls on the bottom of the air cylinders Six Months 1 Lubrication Disconnect the power and air supply to the machine Then remove the end panels Lubricate the bearings on the ends of each laminating roll two per roll with a high temperature grade of bearing grease such as Lubriplate 930 2 or equivalent from a standard grease gun Also lubricate the flange bearing on the bottom secondary drive roll pull roller Lubricate by h
26. ified RIGGERS if any movement of the machine other than rolling on a flat level surface is contemplated The Orca 80 99 Laminator is not designed to be tipped up or sideways in anyway Such action may disturb the exact alignment of the rolling parts of the machine and require extensive re alignment GBC Pro Tech s warranty does not cover malfunction of the equipment due to mis handling and or tipping GBC Pro Tech bears no responsibility for parties who fail to follow these directions Any injury or damage to the machine due to improper moving is the sole responsibility of the mover Before the machine can be rolled off the crate the foot bolts must be freed from the four shipping hold down plates Loosen the lock nut on each of the foot bolts Unscrew the foot bolts from the hold down plates Raise but do not remove the bolts and lock nuts from the foot bracket Atthis time you may wish to remove the hold down plates from the crate to provide unrestricted removal ofthe machine from the crate O GBC Films Group June 2000 Page4 1 Installation Orca 80 99 Operation and Maintenance Manual INSTALL SCREWS UNCRATING DIAGRAM ORCA 80 99 Page 4 2 GBC Films Group June 2000 Orca 80 99 Operation and Maintenance Manual Installation 7 Once the ramps are secured and the hold down plates are removed the machine can be rolled off the crate bottom This will require four people handling
27. into the nip while maintaining paper tension on the image being overlaminated Page 5 26 O GBC Films Group June 2000 Orca 80 99 Operation and Maintenance Manual Operations UNWIND RELEASE PAPER REWIND 3 16 STARTER BOARD 3 16 FOAMBOARD ia ce 3 Chart 2 9B COLD OVERLAMINATE GBC Films Group June 2000 Page 5 27 Orca 80 99 Operation and Maintenance Manual Maintenance MAINTENANCE Introduction WARNING Some maintenance procedures require opening the cabinets while the power and air are still connected to the machine Because of the potential for electrical shock from wiring and crushing of fingers or arms in rotating apparatus only properly trained personnel should perform these tasks CAUTION Never attempt maintenance on an operating machine unless the instructions specifically call for it GBC Pro Tech laminators require minimal maintenance However regular maintenance is essential to keep any piece of precision machinery at peak performance The following procedures are segmented into daily monthly biannual and as required procedures Daily 1 Clean the Laminating Rolls The silicone laminating rolls can be cleaned of dust and dirt by passing an adhesive coated board through the nip Of course the nip should be set for the thickness of the board used A mild dishwashing detergent can also be used to clean the rolls However a better procedure is to use isopropyl
28. ller ON 40 p s i Top Cooling Fans OFF Bottom Brake front OFF NA Bottom Cooling Fans OFF Bottom Clutch front OFF NA Pull Roller Clutch OFF Forward Reverse FORWARD Pull Roller Pressure OFF Speed 2 3 f p m Bottom Brake rear OFF Laminator Roller Shims 3 16 Bottom Clutch rear Pull Roller Shims Helpful Hints Notes Lay the image to be mounted on the board and push the board into the nip while the rolls are not turning Then quickly depress the foot switch to turn the rolls Make sure to maintain good paper tension while mounting the image Page 5 12 GBC Films Group June 2000 Orca 80 99 Operation and Maintenance Manual Operations CHART 2 2B ONE PASS HOT MOUNT GBC Films Group June 2000 Page 5 13 Operations Orca 80 99 Operation and Maintenance Manual PROCESS CONTROL CHART 2 3 Process Hot Mount and Laminate One Pass Materials top bottom 3 16 thick Hot tissue board Front Control Panel Rear Control Panel Adjustments Adjustments Top Brake ON 20 p s i Top Heat ON 245 F 118 C Top Clutch OFF NA Bottom Heat OFF Laminator Roller ON 40 p s i Top Cooling Fans OFF Bottom Brake front OFF NA Bottom Clutch front OFF NA Forward Reverse FORWARD Laminator Roller Shims 3 16 Bottom Clutch rear Pull Roller Shims Helpful Hints Notes Start the overlaminate with a leader board the same thi
29. nual B Shims none C Laminating Roller Pressure 60 PSI 410 kPa D Pull Roller Clutch Pressure On 80 PSI 550 kPa E Pull Roller Down 60 PSI 410 kPa Speed 4 to 6 fpm G Top Roll Temperature 220 230 degrees F 90 110 degrees H Bottom Roll Temperature 220 230 degrees F 90 110 degrees I Cooling Optional J Use of the rear rewind for the finished material is optional It is a good procedure for long runs Ifa rewind is used in this application the clutch pressure should be 15 PSI 2 Procedure A Feed the work into the nip with the leading edge tight and entering the nip evenly from side to side For thin paper from electrostatic printers in roll form it is best to fold over the leading edge approximately 6 inches to create a square leading edge Two Pass Mount and Laminate Hot and Cold Cold Mount Laminate A See charts 2 5 2 5B 2 6 and 2 6B for settings B Assure that the mounting film from the bottom side has the sticky adhesive side riding up around the outside of the bottom laminating roller Procedure Pass 1 A Run the print through to apply adhesive and laminate B Trim to slightly larger than the desired finished size WARNING Take care when repositioning rewind unwind shafts or other heavy parts or materials used in the various web up patterns They are heavy and can cause injury to fingers and or toes if not handled properly Procedure Pass 2
30. owing procedure is applicable to both the top and the bottom feed unwinds 1 Remove the ball detent retaining pins and carefully remove the unwind rewind shaft from its saddles Pay particular attention to the drive side saddles The drive side of the shafts must be oriented so as to not pry on the brake or clutch protrusion To do so would irreparably damage both brakes and clutches 2 Slide the film onto the unwind shaft 3 Install the shaft back into its saddles again paying careful attention to the drive side end of the shaft Return ball detent pins to secure the shaft in its saddles O GBC Films Group June 2000 Page5 5 Operations Orca 80 99 Operation and Maintenance Manual 4 Center the film by sliding it back and forth on the shaft until centered As soon as the film is unwound from the shaft the core support will lock the roll into position 5 Recheck the centering of the film roll with a tape measure WARNING Normal operation of the Orca 80 laminator involves the application of large amounts of heat to the process materials The surfaces of the rolls are at a high enough temperature to cause burns if they are touched Operators are cautioned not to touch lean or fall against the rolls of an operating laminator Do not become unbalanced when working near an operating laminator Heating The following instructions should be employed when heating one or both of the laminating rolls The procedure
31. rca 80 99 is in accordance with all established national and regional electrical codes and standards CAUTION The air supply to the Orca must be clean and dry or the machine will be damaged GBC Pro Tech will not be responsible for damage to the equipment caused by improper connection incorrect power supply or other incorrect electrical installation Before initial power is applied to the machine assure that all toggle switches on the front and rear control panels and the main power circuit breaker inside bottom of the left side cabinet are setto OFF The AC connection is located on the bottom front of the left side cabinet O GBC Films Group June 2000 Page4 3 Installation Orca 80 99 Operation and Maintenance Manual Work Table 6 6 2m x 2m on w heels AIR SUPPLY 24 7 3m ELECTRICAL SUPPLY Work Table 6 6 2m x 2m on w heels Fig 1 1 SUGGESTED WORKSPACE LAYOUT ORCA 80 99 Page 4 4 GBC Films Group June 2000 Orca 80 99 Operation and Maintenance Manual Installation Air Requirements CAUTION Do not use a knife or other sharp object to remove the paper coverings This would cause irreparable damage to the rolls and necessitate their replacement The Orca 80 99 laminator requires filtered air at 2 cubic feet per minute CFM 50 liters minute at a pressure of at least 100 pounds 700 kPa per square inch PSI The air supply must be clean free of dirt and
32. ssure Sensitive Mount Adhesive Materials top bottom 3 mil Gloss Mount Adhesive Front Control Panel Rear Control Panel Adjustments Adjustments Top Brake ON 20 p s i Laminator Roller ON 60 p s i FF Bottom Brake front ON 20 p s i Bottom Cooling Fans O Bottom Clutch front OFF NA Forward Reverse FORWARD Laminator Roller Shims 0 Pull Roller Shims 0 Helpful Hints Notes The encapsulated image will have waves running 90 degrees to the feed of the film This is due to the moisture in the mount adhesive s release liner Once mounted the waves disappear Page 5 18 GBC Films Group June 2000 Orca 80 99 Operation and Maintenance Manual Operations Chart 2 5B TWO PASS HOT OVERLAMINATE WITH PRESSURE SENSITIVE MOUNT ADHESIVE FIRST PASS GBC Films Group June 2000 Page 5 19 Operations Orca 80 99 Operation and Maintenance Manual PROCESS CONTROL CHART 2 6 Process Hot overlaminate with Pressure Sensitive Mount Adhesive Second Pass Materials top bottom 3 16 Foamcore Front Control Panel Rear Control Panel Adjustments Adjustments Laminator Roller OFF NA Bottom Brake front OFF NA Bottom Clutch front OFF NA Forward Reverse REVERSE Laminator Roller Shims N A Pull Roller Shims 3 16 Helpful Hints Notes When mounting keep an even wrap around the upper pull roll to eliminate any wrinkles due to uneven feed of the image During the mounting process
33. that nothing is in the nip area Most GBC Pro Tech machines are designed to heat the lamination rollers Temperatures can be set to over 200 degrees F 100 degrees C Thus there is a danger of a severe burn if the rollers are touched during set up or operation The machines have steel end cabinets that are bolted closed They serve to isolate the electrical and drive system components WARNING Please note All persons working on or near the Orca 80 99 Laminator must be advised of the following If any clothing tools or anything other than film or paper is inadvertently drawn into the nip the action of the rolls may be halted immediately and the top roll lifted by pushing or striking any of the red E Stop switches located at the top of the machine or by stepping on or kicking the E Stop cable located at the bottom of the machine Quick action in this regard can aid in preventing or minimizing injury or machine damage Because of the electrical shock hazard and the chance that a person might get either fingers or clothing into the drive mechanism the cabinets should only be opened by a qualified service person after the machine is shut off and the power disconnected Page 1 2 GBC Films Group June 2000 Orca 80 99 Operation and Maintenance Manual Warranty WARRANTY Limited Warranty CAUTION Unauthorized customer alterations will void this warranty GBC Pro Tech warrants the equipment sold is
34. tion Using a Sled 1 Setup A Refer to charts 2 9 and 2 9B B Set main roll shims to 3 16 2 Procedure A Use a starter board to get the film started and feeding without wrinkles B Lay image on the sled and place it up against the leader board C Feed image through the nip following the leader board into the nip Maintain paper tension on the image until itis through the nip D Cut around the image with a sharp knife to remove it from the leader board GBC Films Group June 2000 Page 5 9 Operations Orca 80 99 Operation and Maintenance Manual PROCESS CONTROL CHART 2 1 Process Materials top bottom Front Control Panel Rear Control Panel Adjustments Adjustments Laminator Roller Top Cooling Fans Helpful Hints Notes Page 5 10 GBC Films Group June 2000 Orca 80 99 Operation and Maintenance Manual Operations 1 REMOVABLE IDLER F FIXED IDLER U UNWIND SHAFT R REWIND M MAIN ROLL P PULL ROLL OUTFEED SLITTER Chart 2 1B IDENTIFICATION DIAGRAM GBC Films Group June 2000 Page 5 11 Operations Orca 80 99 Operation and Maintenance Manual PROCESS CONTROL CHART 2 2 Process Hot Mount One Pass Materials top bottom 3 16 thick Hot tissue coated board Front Control Panel Rear Control Panel Adjustments Adjustments Top Brake OFF Top Heat ON 245 F 118 C Top Clutch OFF NA Bottom Heat OFF Laminator Ro
35. tments Adjustments Laminator Roller ON 30 p s i Bottom Brake front OFF Bottom Clutch front OFF NA Pull Roller Clutch OFF NA Forward Reverse FORWARD Pull Roller Pressure OFF Speed 2 3 f p m Bottom Brake rear OFF Laminator Roller Shims 3 16 Bottom Clutch rear OFF Pull Roller Shims N A Helpful Hints Notes When mounting keep an even wrap around the upper main roll to eliminate any wrinkles due to uneven image feed Page 5 24 GBC Films Group June 2000 Orca 80 99 Operation and Maintenance Manual Operations RELEASE Chart 2 8B TWO PASS COLD OVERLAMINATE WITH PRESSURE SENSITIVE MOUNT ADHESIVE SECOND PASS GBC Films Group June 2000 Page 5 25 Operations Orca 80 99 Operation and Maintenance Manual PROCESS CONTROL CHART 2 9 Process Cold Overlam only using a sled Materials top bottom Pro Gloss 3 16 board to be used for the sled Front Control Panel Adjustments Top Brake Top Clutch Laminator Roller Bottom Brake front Bottom Clutch front Forward Reverse Speed Laminator Roller Shims Helpful Hints Notes ON 40 p s i ON 20 p s i ON 40 p s i OFF NA OFF NA FORWARD 4 6f p m 3 16 Rear Control Panel Adjustments Pull Roller Shims NA Use a starter board of the same thickness as the sled being used to start the laminate into the nip Lay the image on the sled and follow the leader board
36. to this product through any slots as they may touch dangerous voltage points or short out parts that could result in a risk of fire or electric shock Never spill liquid of any kind on the product 9 Do not attempt to service this product yourself as opening or removing covers may expose you to dangerous voltage points or other risks Refer all servicing to service personnel 10 Unplug this product from the wall outlet and refer servicing to qualified service personnel under the following conditions A When the power cord is damaged or frayed If liquid has spilled into the product C If the product has been exposed to rain or water WARNING Never place fingers or arms between the rollers when they are turning or when the rollers are in the closed position D If the product does not operate normally when the operating instructions are followed Adjust only those controls that are covered by the operating instructions since improper adjustment of other controls may result in damage and will often require extensive work by a qualified technician to restore the product to normal operation E If the product exhibits a distinct change in performance indicating a need for service Safety Information WARNING Itis vital that everyone working around the laminator rolls avoid wearing loose fitting clothing ties or dangling jewelry which could be caught in the nip The GBC Pro Tech laminator has been designed with
37. w Orca 80 99 Laminator please follow this procedure exactly 1 The top of the crate is the first piece to be removed see diagram on page 4 3 2 Next remove one side of the crate see diagram At this point it is necessary to have someone support the remaining side of the crate while the remaining end is being removed Maintain support of the side until all mounting screws are removed and the side is off the crate 3 Remove the end of the crate see diagram CAUTION Do not use a knife or other sharp instrument to remove any protective covering This could cause irreparable damage to the machine 4 Remove the shrink wrap from the machine and its contents 5 Once the shrink wrap is off remove any accessories from the crate While doing this take care not to scuff the machine 6 When all the accessories have been removed from the crate you will notice that there are two ramps that are bolted down to the crate bottom these will need to be removed using the phillips head screwdriver The ramps must then be secured to the edge of the crate bottom using the screws left over from crate disassembly see diagram PLEASE NOTE The Orca 80 99 Laminator is a large and heavy piece of mechanical equipment Casual movement of equipment of this type can be hazardous to the average person and poses the potential of serious damage to the machine It will be necessary to employ qualified and trained personnel licensed cert
38. will harden within an hour 3 Do not allow liquid silicone adhesives to contact the top or bottom silicone roll These materials will bond to the roll in much less than one hour If some adhesive does get on the roll wipe it off IMMEDIATELY using isopropyl alcohol 4 The laminating rolls will develop flat spots if left in contact with each other when not in use Always insert the shims when shutting off the laminator Do not rely on the air supply to keep the top roller in the raised position as the air supply can fail at any time 5 Use a 100 percent cotton terry cloth to remove heat activated laminating residue while the rolls are hot Follow this procedure every time heat activated laminates are used WARNING 1 Never place fingers or arms between the rollers both main and pull or in roller slots no matter what the operational status the machine is in 2 It is vital that everyone working around the laminator rolls avoid wearing loose fitting clothing ties or dangling jewelry which could be caught in the nip WARNING Extra caution must be used when operating the laminator with the provided foot switch The foot switch acts as an over ride to the photoelectric eye i e it allows the rolls to continue operation even if the photoelectric eye detects an obstruction near the nip This function is necessary a to allow initial hand feeding of process materials to the rolls and b to prevent damage to the pro
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