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Operations

Orca 80-99 Operation and Maintenance Manual

© GBC Films Group June 2000

(I) REMOVABLE IDLER

(F) FIXED IDLER

(U) UNW I N D S HAF T

(R) REWIND

(M) MAIN ROLL

(P) PULL ROLL

U

U

U

F

F

F

F

F

I

R

R

R

M

M

P

P

OUTFEED

SLIT T ER

IDENTIFICATION DIAGRAM

Chart 2-1B

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Summary of Contents for 80-99

Page 1: ...ech 4151 Anderson Road DeForest WI 53532 Revision Ph 608 246 8844 Fx 608 246 8645 ORCA 80 99 OPERATION MAINTENANCE MANUAL June 2000 GBC Pro Tech Do not duplicate without written permission Part number...

Page 2: ...Table of Contents Section 1 Safety Safety features 1 1 Section 2 Warranty Limited warranty information 2 1 Exclusions to the warranty 2 1 Section 3 Specifications Section 4 Installation Uncrating 4 1...

Page 3: ...1 Front control panel diagram 5 2 Rear control panel diagram 5 3 Front control panel 5 4 Rear control panel 5 4 Setup 5 5 Processes 5 7 Process control chart blank 5 10 Process control diagram blank 5...

Page 4: ...Diagram 2 5 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...

Page 5: ...Page IV Table of Contents Orca 80 99 Operation and Maintenance Manual GBC Pro Tech June 2000 Section 6 Maintenence Daily 6 1 Monthly 6 1 Six Month 6 2 Chain Diagram 6 3...

Page 6: ...not attempt to service this product yourself as openingorremovingcoversmayexposeyoutodangerous voltagepointsorotherrisks Referallservicingtoservice personnel 10 Unplug this product from the wall outl...

Page 7: ...he up and down motion of the top laminator roll Before turning this switch to the DOWN position assure that nothing is in the nip area Most GBC Pro Tech machines are designed to heat the lamination ro...

Page 8: ...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...

Page 9: ...re controlled by state of the art infrared sensors with closed loop digital control systems independently adjustable for both top and bottom rolls LaminatingOpening 1_ 4 75cm maximumopeningcontrolledw...

Page 10: ...ng this take care not to scuff themachine 6 Whenalltheaccessorieshavebeenremovedfromthe crate you will notice that there are two ramps that are bolted down to the crate bottom these will need to be re...

Page 11: ...Page 4 2 Installation GBC Films Group June 2000 Orca 80 99 Operation and Maintenance Manual 23 in 59cm 3 2 INSTALL SCREWS UNCRATING DIAGRAM 5 ORCA 80 99 1 4...

Page 12: ...s 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 Afterbothsideshavebeenleveledfront to...

Page 13: ...000 Orca 80 99 Operation and Maintenance Manual SUGGESTED WORKSPACE LAYOUT Fig 1 1 AIR SUPPLY ELECTRICAL SU PPLY 20 6m 24 7 3m 10 3m 4 1 2m 10 3m 3 1m ORCA 80 99 FRONT REAR Work Table 6 X 6 2m x 2m on...

Page 14: ...riate Airisfedtothemachineviaa1 4 inchquick disconnect male connector This connector is located below the cabinet on the left side of the machine Once the air supplyandelectricalpowerareconnectedtothe...

Page 15: ...wipe it off IMMEDIATELY using isopropylalcohol 4 Thelaminatingrollswilldevelopflatspotsifleftin contact with each other when not in use Always insert theshimswhenshuttingoffthelaminator Donotrelyon th...

Page 16: ...OFF S MOTOR CONTROLS F A R E T S REV R E 0 L W STOP FWD JOG RUN O N ADJUST O N ADJUST ADJUST O N ADJUST O N ADJUST FRONT CONTROL PANEL TOP UNWINDS 3 ON OFF AIR PRESSURE ADJUSTMENT TOP REWIND ON OFF U...

Page 17: ...F ON OFF ON OFF REAR CONTROL PANEL BOTTOM HEATER BOTTOM HEATER CONTROL ON OFF ON OFF BOTTOM FAN BANK ON OFF TOP FAN BANK ON OFF TOP HEATER CONTROL TOP HEATER PULL ROLL CLUTCH PRESSURE GAUGE PRESSURE G...

Page 18: ...ONTROL Adjusts the speed of the machinefromzerotomaximumasthecontrolisturned clockwise I SPEED READOUT Digital readout of the machine speed and total throughput in either metric or standard units J ON...

Page 19: ...tom unwinds Theprocessofloadingandaligningfilmisthesamefor both the top and the bottom There are two important pointstorememberwhenloadingfilm CAUTION Assure that film is always mounted so that the ad...

Page 20: ...own 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...

Page 21: ...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 isheldinplace B Put a piece...

Page 22: ...hedsize 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 no...

Page 23: ...ng 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 feedingwithoutwrinkles B Lay image on the sled and place it...

Page 24: ...Control Panel Adjustments Rear Control Panel Adjustments Top Brake Top Heat Top Clutch Bottom Heat Laminator Roller Top Cooling Fans Bottom Brake front Bottom Cooling Fans Bottom Clutch front Pull Rol...

Page 25: ...80 99 Operation and Maintenance Manual GBC Films Group June 2000 I REMOVABLE IDLER F FIXED IDLER U UNWIND SHAFT R REWIND M MAIN ROLL P PULL ROLL U U U F F F F F I R R R M M P P OUTFEED SLITTER IDENTIF...

Page 26: ...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 NA Forward Reverse FORWARD Pull Roller Pressure OFF NA Speed 2...

Page 27: ...Page 5 13 Operations Orca 80 99 Operation and Maintenance Manual GBC Films Group June 2000 245 F COLD ONE PASS HOT MOUNT 118 C IMAGE CHART 2 2B...

Page 28: ...NA Laminator Roller 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 NA Forward Reverse FORWARD Pull Roller Pressur...

Page 29: ...Page 5 15 Operations Orca 80 99 Operation and Maintenance Manual GBC Films Group June 2000 245 F COLD ONE PASS HOT MOUNT AND LAMINATE 118 C IMAGE CHART 2 3B...

Page 30: ...p Brake ON 20 p s i Top Heat ON 230o F 110o C Top Clutch ON 20 p s i Bottom Heat ON 230o F 110o C Laminator Roller ON 60 p s i Top Cooling Fans ON Bottom Brake front ON 20 p s i Bottom Cooling Fans ON...

Page 31: ...Page 5 17 Operations Orca 80 99 Operation and Maintenance Manual GBC Films Group June 2000 230 F UNW IND ENCAPSULATION 230 F Chart 2 4B 110 C 110 C...

Page 32: ...NA Bottom Heat OFF NA Laminator Roller ON 60 p s i Top Cooling Fans OFF Bottom Brake front ON 20 p s i Bottom Cooling Fans OFF Bottom Clutch front OFF NA Pull Roller Clutch ON 80 p s i Forward Reverse...

Page 33: ...5 19 Operations Orca 80 99 Operation and Maintenance Manual GBC Films Group June 2000 230 F UNW IND TWO PASS HOT OVERLAMINATE COLD WITH PRESSURE SENSITIVE MOUNT ADHESIVE FIRST PASS Chart 2 5B 110 C UN...

Page 34: ...oling Fans OFF Bottom Brake front OFF NA Bottom Cooling Fans OFF Bottom Clutch front OFF NA Pull Roller Clutch ON 40 p s i Forward Reverse REVERSE Pull Roller Pressure ON 30 p s i Speed 2 3 f p m Bott...

Page 35: ...age 5 21 Operations Orca 80 99 Operation and Maintenance Manual GBC Films Group June 2000 COLD COLD WITH PRESSURE SENSITIVE MOUNT ADHESIVE SECOND PASS TWO PASS HOT OVERLAMINATE RELEASE LINER Chart 2 6...

Page 36: ...ar Control Panel Adjustments Top Brake ON 40 p s i Top Heat ON 115 F 46o C Top Clutch ON 20 p s i Bottom Heat OFF NA Laminator Roller ON 40 p s i Top Cooling Fans OFF Bottom Brake front ON 20 p s i Bo...

Page 37: ...a 80 99 Operation and Maintenance Manual GBC Films Group June 2000 REW IND PAPER RELEASE 46 C COLD UNW IND WITH PRESSURE SENSITIVE MOUNT ADHESIVE FIRST PASS TWO PASS COLD OVERLAMINATE MOUNT ADHESIVE U...

Page 38: ...A Top Heat OFF NA Top Clutch OFF NA Bottom Heat OFF NA Laminator Roller ON 30 p s i Top Cooling Fans OFF Bottom Brake front OFF NA Bottom Cooling Fans OFF Bottom Clutch front OFF NA Pull Roller Clutch...

Page 39: ...5 25 Operations Orca 80 99 Operation and Maintenance Manual GBC Films Group June 2000 46 C COLD WITH PRESSURE SENSITIVE MOUNT ADHESIVE SECOND PASS TWO PASS COLD OVERLAMINATE RELEASE LINER Chart 2 8B 1...

Page 40: ...Laminator Roller 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 NA Forward Reverse FORWARD Pull Roller Pressure O...

Page 41: ...e 5 27 Operations Orca 80 99 Operation and Maintenance Manual GBC Films Group June 2000 REW IND PAPER RELEASE 115 F COLD UNW IND IMAGE 3 16 FOAMBOARD 3 16 STARTER BOARD COLD OVERLAMINATE Chart 2 9B 46...

Page 42: ...pped 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 adj...

Page 43: ...Months 1 Lubrication Disconnect the power and air supply to the machine Then remove the end panels Lubricatethebearingsontheendsofeachlaminating roll two per roll with a high temperature grade of bea...

Page 44: ...Page 6 3 Maintenance Orca 80 99 Operation and Maintenance Manual GBC Films Group June 2000 CHAIN TENSION DIAGRAM PRIMARY SECONDARY CHAIN 3 CHAIN 4 CHAIN TENSIONERS...

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