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Operation

ORCA-III Operation Manual



GBC Pro-Tech 1997 October

3-2

In addition, the ORCA-III is equipped with two
Emergency Stop Kick Cables located at the lower
front and back of the laminator. Either of these, if
stepped on or kicked, stops the laminator. To restart,
push the reset button and reactivate the heaters, fans,
roll motion, and roll position controls.

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Emergency Stop Kick Cables

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Summary of Contents for OORCA-III

Page 1: ...OP AR R E T D U R G E N C E NO T AU S EMER G E N CY ST OP AR R E T D U R G E N C E NOT AUS EM E R G E N CY ST OP ARR E T D U R G E N CE NOT AUS EM E R G E N CY ST OP ARR E T D U R G E N CE 15 20 25 30 ST OP AU TO FW D RE V PO WE R 1 O HE AT RO LL PR ES SU RE MO TO R CO NT RO LS PRO TEC H Eng inee ring Mad ison WI 608 246 8844 LA MINA TO R RO LL CO NT RO LS 20 100 40 80 SP EE D 0 3 6 9 12 15 18 AD ...

Page 2: ...blication 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 r...

Page 3: ...g 2 6 Startup 2 6 6HFWLRQ 2SHUDWLRQ Safety 3 1 Operator Controls 3 3 Operator Controls 3 3 Front Control Panel 3 3 Rear Control Panel 3 4 Setup 3 4 Laminator Roll Pressure 3 4 Loading the Film 3 5 Positioning the Film 3 5 Heating 3 6 Cooling 3 6 Paper Tips 3 6 Process Control Charts 3 7 Mounting Only 3 7 Setup 3 7 Procedure 3 7 Mounting Laminating 3 7 Setup 3 7 Procedure 3 7 Encapsulation 3 8 Setu...

Page 4: ...tion Second Pass Main Rolls Hot 3 10 With Hot Main Rolls 3 10 PROCESS CONTROL CHART 3 1 3 11 PROCESS CONTROL DIAGRAM 3 1B 3 12 PROCESS CONTROL CHART 3 2 3 13 PROCESS CONTROL DIAGRAM 3 2B 3 14 PROCESS CONTROL CHART 3 3 3 15 PROCESS CONTROL DIAGRAM 3 3B 3 16 PROCESS CONTROL CHART 3 4 3 17 PROCESS CONTROL DIAGRAM 3 4B 3 18 PROCESS CONTROL CHART 3 5 3 19 PROCESS CONTROL DIAGRAM 3 5B 3 20 PROCESS CONTR...

Page 5: ...BC Pro Tech Products 3 37 All Pressure Sensitive Materials 3 37 Lamination 3 37 Mounting 3 37 Vinyl Transfer 3 37 6HFWLRQ 0DLQWHQDQFH DQG 7URXEOHVKRRWLQJ Cleaning 4 1 Adjusting the Main Roll Nip 4 3 Adjusting the Pull Roll Nip 4 4 Chain Tensioning and Take Up 4 5 Adjusting the Air Cylinder Rate 4 6 Lubrication 4 8 Contacting Technical Support 4 8 Schematic Diagram 4 9 Pneumatic Diagram 4 2 Output ...

Page 6: ...ownward pressure on the top roll is capable of producing forces greater than 1000 pounds 454 kg 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 laminating 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 mot...

Page 7: ...TE CH Enginee ring Madison WI 608 246 8844 LAM INAT OR ROL L CON TRO LS 20 100 40 80 SPEE D 0 3 6 9 12 15 18 ADJ TOP 1 O BOTT OM FAN TABL E by Pro Tech To be serv iced only by train ed and auth orize d pers onne l Lock out powe r befo re serv icing HAZ ARD OUS VOL TAG E DA NG ER GE FA HR 1994 Hazard Communicat ion Systems Inc 800 748 0241 Reorder No 5025 PT NOT AUS EMER G E N CY ST OP ARR E T D U ...

Page 8: ...ol or a rubber cement eraser to clean the laminating rolls Harsh chemicals like toluene acetone or MEK destroy the silicone covering of the rolls CAUTION Raise the upper main roll when the laminator is not in operation Prolonged contact can damage the rolls CAUTION Excess pressure can damage the laminating rolls Always select the minimum roll pressure necessary to complete the task CAUTION If sili...

Page 9: ...l injury or damage due to moving the laminator improperly WARNING Only a qualified electrician should connect power to the laminator You can be severely shocked electrocuted or cause a fire if power is improperly applied WARNING Do not operate the 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...

Page 10: ...ro Tech 1997 October 1 5 DXWLRQ DUQLQJ DEHO RFDWLRQV Posted at various locations on your ORCA III Laminator are important safety labels PAY CAREFUL ATTENTION TO THESE LABELS AT ALL TIMES Figure 1 3 shows the location of each of these labels ...

Page 11: ...D 0 3 6 9 12 15 18 AD J TO P 1 O BO TTO M FAN TAB LE 1994 HCS Inc 800 748 0241 Reorder No 1033R PT WARNING ACHTUNG MISE EN GARDE by Pro Tech To be se rvi ce d on ly by tra ine d an d au tho riz ed pe rso nn el Lo cko ut po we r be for e se rvi cin g HA ZA RD OU S VO LT AG E DANGER GEFA HR 1994 Hazard Commu nicatio n System s Inc 800 748 0241 Reorde r No 5025 P T NO T AUS EMER G E N CY ST OP ARR E ...

Page 12: ... and vapor free environment to operate properly It must not be located where there is air blowing directly on the machine WARNING 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 laminator CAUTION Do not locate the laminator where air i...

Page 13: ... controls Either problem can cause the laminator to malfunction It is the customer s responsibility to provide appropriate 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 laminator A standard light duty to horse power 1 kW electric air compressor wit...

Page 14: ...Wall 4 x 6 122 cm x 182 cm Work Table on Wheels Table Height 35 3 4 90 5 91 5 cm 2 8 81 cm 8 8 264 cm 8 8 264 cm Rear Front 20 609 cm Electrical Supply Air Supply 13 396 cm 4 x 6 122 cm x 182 cm Work Table on Wheels Table Height 35 3 4 90 5 91 5 cm Figure 2 1 Laminator Space Requirements ...

Page 15: ... nnel Locko ut powe r befor e servic ing HAZA RDO US VOLT AGE DA NG ER GE FA HR 1994 Hazard Communicatio n Systems Inc 800 748 0241 Reorder No 5025 PT NOT AUS EMER G E N CY ST OP ARR E T D U R G E N C E NOT AUS EMER G E N CY ST OP ARR E T D U R G E N C E NOT AUS EM E R G E N CY ST OP ARR E T D U R G E N CE NOT AUS EM E R G E N CY ST OP ARR E T D U R G E N CE 15 20 25 30 STOP AUTO SPEE D 0 3 6 9 12...

Page 16: ...d NOTE A word about international shipments As these are heavy pieces of equipment GBC Pro Tech takes every precaution to ensure that our laminators 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 corrosion protection This protective film is wrapped around the machine and completely sealed In addit...

Page 17: ... is level tighten down the top nuts on the foot brackets to lock the pads in their current position 6WDUWXS The first time the laminator is started and every time it is serviced you should use the following checklist to confirm that the unit is operating properly and that all safety mechanisms are functioning Startup Checklist Start the laminator and go through the following checklist Are the emer...

Page 18: ... repeat the test for the back emergency stop kick cable WARNING Never operate the laminator unless both of the emergency stop kick cables are functioning properly You can be crushed or burned Is the motor functioning Test the motor at various speeds ranging from 0 15 At 0 the rolls should stop turning Run the motor in both forward and reverse Are the heaters working Verify that the top heater cont...

Page 19: ...Installation ORCA III Operation Manual GBC Pro Tech 1997 October 2 8 Blank Page ...

Page 20: ...if the rolls are touched during set up operation or servicing The ORCA III Laminator 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 technician should open these cabinets The laminator is equipped with four emergency stop buttons located on the top of either side of the laminator Any of these if...

Page 21: ...RES SURE MOT OR CON TRO LS PRO TE CH Enginee ring Madison WI 608 246 8844 LAM INAT OR ROL L CON TRO LS 20 100 40 80 SPEE D 0 3 6 9 12 15 18 ADJ TOP 1 O BOTT OM FAN TABL E by Pro Tech To be serv iced only by train ed and auth orize d pers onne l Lock out powe r befo re serv icing HAZ ARD OUS VOL TAG E DA NG ER GE FA HR 1994 Hazard Communicat ion Systems Inc 800 748 0241 Reorder No 5025 PT NOT AUS E...

Page 22: ...ghput in either metric or standard units 2 SPEED ADJUSTMENT Adjusts the speed of the machine from zero to maximum as the control is turned clockwise 3 UPPER HEATER CONTROLLER Provides a readout of the temperature of the upper laminating roll and the set point for the desired temperature 4 UPPER ROLL HEAT ON OFF Turns the heater controller for the top laminating roll on or off 5 MAIN ROLL AIR PRESS...

Page 23: ...rns the cooling fans on or off 6 FOOTSWITCH CONTINUOUS RUN Changes control of the machine drive from the footswitch to continuous run 7 PULL ROLL UP DOWN Sets the pull roll to the up load or down operate position 8 PULL ROLL CLUTCH ON OFF Turns the pull roll clutch on or off 6HWXS Setup of the ORCA III Laminator is quick and straightforward when instructions are followed exactly CAUTION Always use...

Page 24: ...tal when two films are fed together If the two films are not aligned feed problems wrinkles and other assorted troubles will occur CAUTION Carefully align the two films being fed into the nip If not you will obtain poor results 3RVLWLRQLQJ WKH LOP The following procedure is applicable to all the feed unwinds Tools required 5 16 T handle wrench Tape measure To position the film 1 Open the top unwin...

Page 25: ...e has been reached the machine is ready to use 6 The ORCA III can be used for cold mounting and laminating while maintaining the temperature of the main laminating rolls by using the output rolls as a laminator by feeding prints from the rear for a quick change over between hot and cold laminating RROLQJ The following is the fastest way to cool down the machine 1 Set the heater switches to OFF 2 P...

Page 26: ...ed on Orca Film Orca Board and typical prints 0RXQWLQ J 2QO 6HWXS 1 See process charts 3 1 3 2 and diagram 3 2b 2 Shims Set to the thickness of the material being used for mounting 3 Upper Laminator Roll Pressure 40 PSI 275 kPa 4 Speed 3 fpm 90 cpm 5 Upper Laminator Roll Heat 230 F 110 C 3URFHGXUH 1 Lay the print on the board Using a tack iron tack the leading edge of the print down onto the board...

Page 27: ... or back of the laminator 6HWXS 1 See process charts 3 5 3 6 3 7 and 3 8 and diagrams 3 5b 3 6b 3 7b and 3 8b for film mounting instructions and machine adjustments 2 Ensure that the mounting film from the bottom side has the sticky adhesive side riding up around the outside of the bottom laminating roll 3URFHGXUH 3DVV 1 Run the print through to apply adhesive and laminate 2 Trim to slightly large...

Page 28: ...aising the pull roll Web the laminate around the upper pull roll Be sure it is smooth on the roll then lower the roll 5 Add infeed and outfeed slitters as needed WARNING The blades on both the infeed and outfeed slitters are razor sharp You can cut yourself severely 9LQ O 7UDQVIHU 1 See process chart 3 11 and diagram 3 11b for film mounting instructions and machine adjustments 2 Web the vinyl up a...

Page 29: ...rt 3 12 and diagram 3 13b for film mounting instructions and machine adjustments 2 Install the brake adapter on the rear rewind 3 Bring the vinyl up over the bottom lamination roll and through the main rolls 4 Tape the overlaminate release liner to the upper rewind 5 Web the overlaminate material around the upper pull roll and lower it to begin overlamination ...

Page 30: ...rward Roll Up Down Shim Dial Roll Pressure Top Temp Set Top Heater On Off Bottom Temp Set Bottom Heater On Off REAR CONTROL SETTINGS Pull Clutch On Off Pull Roll Up Down Pull Clutch Pressure Pull Roll Pressure Shim Dial Cooling See Chart 3 1B for Webbing Outline Special Instructions __________________________________________________________ _________________________________________________________...

Page 31: ...66 21752 5 0 IDENTIFICATION DIAGRAM C U U R U R R R P P F C F I I I I M M F F U I Removable Idler F Fixed Idler U Unwind Shaft R Rewind M Main Roll P Pull Roll C Cooling Tube S Slitter Idler Large Table Outfeed Slitter Infeed Slitter Small Table I I S S I U Outfeed Slitter ...

Page 32: ... Down Shim Dial 3 16 48 cm Roll Pressure psi 40 Top Temp Set 230 F 110 C Top Heater On Off On Bottom Temp Set 32 F 0 C Bottom Heater On Off On REAR CONTROL SETTINGS Pull Clutch On Off Pull Roll Up Down Up Pull Clutch Pressure psi Pull Roll Pressure psi Shim Dial Cooling No See Chart 3 2B for Webbing Outline Special Instructions __________________________________________________________ ___________...

Page 33: ...on ORCA III Operation Manual GBC Pro Tech 1997 October 3 14 352 66 21752 5 0 ONE PASS MOUNT HEAT ACTIVATED ADHESIVE Hot Dial Nip Height Hot or Cold Use release liner if print is heat sensitive Print Orca Board ...

Page 34: ...n Down Shim Dial 3 16 48 cm Roll Pressure psi 40 Top Temp Set 230 F 110 C Top Heater On Off On Bottom Temp Set 32 F 0 C Bottom Heater On Off On REAR CONTROL SETTINGS Pull Clutch On Off Pull Roll Up Down Up Pull Clutch Pressure psi Pull Roll Pressure psi Shim Dial Cooling No See Chart 3 3B for Webbing Outline Special Instructions __________________________________________________________ __________...

Page 35: ...Operation ORCA III Operation Manual GBC Pro Tech 1997 October 3 16 352 66 21752 5 0 ONE PASS MOUNT AND LAMINATE Hot Dial Nip Height Hot or Cold Print Over laminate Orca Board ...

Page 36: ...Down Shim Dial 0 Roll Pressure psi 80 Top Temp Set 220 F 104 C Top Heater On Off On Bottom Temp Set 220 F 104 C Bottom Heater On Off On REAR CONTROL SETTINGS Pull Clutch On Off On Pull Roll Up Down Down Pull Clutch Pressure psi 80 Pull Roll Pressure psi 80 Shim Dial 0 Cooling On See Chart 3 4B for Webbing Outline Special Instructions __________________________________________________________ _____...

Page 37: ...1752 5 0 ENCAPSULATION Laminate Laminate Paper Hot Hot Optional Laminate Large Table Optional Rewind Optional Infeed Slitter 10 Mil Film DETAIL Optional Outfeed Slitter Optional Laminate Web Film Underneath This Idler When Using 10 Mil Film See Detail Optional Outfeed Slitter ...

Page 38: ...wn Down Shim Dial 0 Roll Pressure psi 80 Top Temp Set 230 F 104 C Top Heater On Off On Bottom Temp Set 230 F 104 C Bottom Heater On Off On REAR CONTROL SETTINGS Pull Clutch On Off On Pull Roll Up Down Down Pull Clutch Pressure psi 80 Pull Roll Pressure psi 80 Shim Dial 0 Cooling See Chart 3 5B for Webbing Outline Special Instructions __________________________________________________________ _____...

Page 39: ... ORCA III Operation Manual GBC Pro Tech 1997 October 3 20 352 66 21752 5 0 ENCAPSULATION ENVELOPE FEED Laminate Hot Hot Optional Rewind Optional Outfeed Slitter Optional Laminate Optional Laminate Laminate Print ...

Page 40: ... Reverse Forward Forward Roll Up Down Down Shim Dial 0 Roll Pressure psi 80 Top Temp Set 220 F 104 C Top Heater On Off On Bottom Temp Set 32 F 0 C Bottom Heater On Off On REAR CONTROL SETTINGS Pull Clutch On Off On Pull Roll Up Down Down Pull Clutch Pressure psi 80 Pull Roll Pressure psi 80 Shim Dial 3 16 48 cm Cooling See Chart 3 6B for Webbing Outline Special Instructions _______________________...

Page 41: ... Mount Adhesive Hot Cold Optional Rewind of Finished Product Optional Infeed Trim Rewind Optional Paper on Core Laminate Optional Outfeed Trim Optional Mount Adhesive Optional Mount Adhesive Optional Outfeed Trim Rewind Optional Outfeed Trim Paper Sheet Feed Hand Wind on Core Tip Keep Leading Edge Straight Parallel to Roll ...

Page 42: ...n Reverse Forward Reverse Roll Up Down Up Shim Dial 3 16 Roll Pressure psi Top Temp Set Top Heater On Off On Off Bottom Temp Set Bottom Heater On Off Off REAR CONTROL SETTINGS Pull Clutch On Off On Pull Roll Up Down Down Pull Clutch Pressure psi 80 Pull Roll Pressure psi 20 50 Shim Dial 3 16 48 cm Cooling See Chart 3 7B for Webbing Outline Special Instructions _____________________________________...

Page 43: ...o Tech 1997 October 3 24 352 66 21752 5 0 TWO PASS MOUNT AND LAMINATE SECOND PASS If Hot Can Use Main Rolls If Cold Dial Nip Height Running Positions Release Liner Tack Lead In Edge to Board Starting Positions Release Liner Orca Board Shim Dial ...

Page 44: ...Up Down Up Shim Dial 0 Roll Pressure psi Top Temp Set Top Heater On Off Bottom Temp Set Bottom Heater On Off REAR CONTROL SETTINGS Pull Clutch On Off On Pull Roll Up Down Down Pull Clutch Pressure psi 80 Pull Roll Pressure psi 80 Shim Dial 0 Cooling See Chart 3 8B for Webbing Outline Special Instructions __________________________________________________________ ___________________________________...

Page 45: ...n Manual GBC Pro Tech 1997 October 3 26 352 66 21752 5 0 COLD MOUNT LAMINATE WHEN MAIN ROLLS ARE HOT ELIMATES COSTLY HEAT UP AND COOL DOWN TIME Mount Adhesive Cold Laminate Hot Hot Optional Mount Adhesive Optional Mount Adhesive ...

Page 46: ...Roll Up Down Down Shim Dial 0 Roll Pressure psi 80 Top Temp Set Top Heater On Off Off Bottom Temp Set Bottom Heater On Off Off REAR CONTROL SETTINGS Pull Clutch On Off On Pull Roll Up Down Down Pull Clutch Pressure psi 80 Pull Roll Pressure psi 80 Shim Dial 0 Cooling See Chart 3 9B for Webbing Outline Special Instructions __________________________________________________________ _________________...

Page 47: ...C Pro Tech 1997 October 3 28 352 66 21752 5 0 COLD LAMINATION Mount Adhesive Cold Cold Optional Rewind Optional Infeed Slitter Optional Edge Trim Rewind Optional Outfeed Slitter Optional Paper Wound on Core Pressure Sensitive Laminate Paper ...

Page 48: ... Down Shim Dial All the way up Roll Pressure psi 90 Top Temp Set 290 F 140 C Top Heater On Off On Bottom Temp Set 32 F 0 C Bottom Heater On Off On REAR CONTROL SETTINGS Pull Clutch On Off On Pull Roll Up Down Down Pull Clutch Pressure psi 50 Pull Roll Pressure psi 80 Shim Dial 0 Cooling On See Chart 3 10B for Webbing Outline Special Instructions ____________________________________________________...

Page 49: ... ROLL TRANSFER AND LAMINATE ONE PASS SLITTING INFEED AND OUTFEED Vinyl Hot Cold Rewind of Finished Product Transfer Paper Infeed Trim Transfer Paper Cutoff Rewind Outfeed Trim Transfer Paper Unwind Overlaminate Rewind Transfer Paper Optional Vinyl Rewind Laminate Paper Optional Vinyl ...

Page 50: ...n Shim Dial All the way up Roll Pressure psi 90 Top Temp Set 290 F 140 C Top Heater On Off On Bottom Temp Set 32 F 0 C Bottom Heater On Off On REAR CONTROL SETTINGS Pull Clutch On Off On Pull Roll Up Down Down Pull Clutch Pressure psi 50 Pull Roll Pressure psi 80 Shim Dial 0 Cooling On See Chart 3 11B for Webbing Outline Special Instructions ________________________________________________________...

Page 51: ...Operation ORCA III Operation Manual GBC Pro Tech 1997 October 3 32 352 66 21752 5 0 Optional Vinyl Hot Cold Optional Vinyl Vinyl Transfer Paper ...

Page 52: ...n Shim Dial All the way up Roll Pressure psi 90 Top Temp Set 290 F 140 C Top Heater On Off On Bottom Temp Set 32 F 0 C Bottom Heater On Off On REAR CONTROL SETTINGS Pull Clutch On Off On Pull Roll Up Down Down Pull Clutch Pressure psi 50 Pull Roll Pressure psi 80 Shim Dial 0 Cooling On See Chart 3 12B for Webbing Outline Special Instructions ________________________________________________________...

Page 53: ...Operation ORCA III Operation Manual GBC Pro Tech 1997 October 3 34 352 66 21752 5 0 ROLL TO ROLL TRANSFER ...

Page 54: ...Reverse Roll Up Down Up Shim Dial Roll Pressure psi Top Temp Set Top Heater On Off Bottom Temp Set Bottom Heater On Off Off REAR CONTROL SETTINGS Pull Clutch On Off On Pull Roll Up Down Down Pull Clutch Pressure psi 80 Pull Roll Pressure psi 80 Shim Dial 0 Cooling No See Chart 3 13B for Webbing Outline Special Instructions __________________________________________________________ ________________...

Page 55: ... October 3 36 352 66 21752 5 0 ROLL TO ROLL COLD OVERLAMINATION Hot Cold Add Brake Pad Infeed Slitter Now Becomes Outfeed Slitter Rewind of Finished Product Transferred Image On Vinyl Pressure Sensitive Overlaminate Edge Trim Rewind Rewind Laminate Paper ...

Page 56: ...vering usually seen with these products becomes less evident or may even disappear DPLQDWLRQ Most laminating on the ORCA III is done with 80 psi on the main laminator roll and 80 psi on both the pull roll clutch and the pull rolls This may vary with the thickness of the paper s used The thick papers traditionally need a full 75 80 psi The thinner papers such as tissue papers or light bond papers c...

Page 57: ...Operation ORCA III Operation Manual GBC Pro Tech 1997 October 3 38 Blank page ...

Page 58: ...gent Rubber cement eraser optional Several 100 cotton terry cloths Protective rubber gloves To clean the laminator rolls WARNING Exercise extreme caution while cleaning the laminator You can be caught in the turning rolls and crushed or burned 1 While the laminator is at normal operating temperature put on the rubber gloves and using a rubber cement eraser remove any heat activated adhesive from t...

Page 59: ...estroy the silicone covering of the rolls 4 With the laminator rolls no hotter than 110 ºF remove dust and dirt from the silicone laminating rolls by running an adhesive coated board through the laminator Be sure to set the nip for the thickness of the board used 5 Allow the laminator to cool To clean the cabinet and covers WARNING Remove power from the laminator and make sure it won t be reapplie...

Page 60: ... 15 20 25 30 Adjusting Collar Shaft Lock Collar Button Head Screw Figure 4 1 Main Roll Nip Setting Assembly 3 Set the main roll pressure to 30 PSI on the front control panel 4 Screw the adjusting collars down until they seat 5 Raise the main roll 6 Without moving the adjusting collars draw a zero on each collar scale 7 Using the 1 16 hex wrench loosen the three button head screws on the adjusting ...

Page 61: ...in place 2 Make sure that the machine has both power and air It is also necessary to ensure that the up down rates of the upper pull roll are even prior to setting the nip If they are not follow the rate adjusting procedure later in this section 3 Raise the upper pull roll 4 Set the nip adjuster on each end of the laminator to zero View the setting on the interior wall of the laminator not from in...

Page 62: ... You could be severely shocked electrocuted or get your fingers caught in the drive mechanisms 1 Open the drive side cabinet cover using 5 32 hex wrench by removing the four screws holding the cover in place 2 Loosen the nut that secures the inner chain tension adjuster sprocket using the 1 1 8 wrench Inner Chain Tension Adjuster Sprocket Motor Sprocket Inner Chain Inner Chain Take Up Outer Chain ...

Page 63: ...isms 1 Open the drive side cabinet cover using the 5 32 hex wrench by removing the four screws holding the cover in place 2 Tighten the nut that secures the outer chain tension adjuster sprocket using the 1 1 8 wrench 3 Move the adjuster sprocket until there is approximately play measured at the outer chain tension check location 4 Tighten the nut that secures the outer chain tension adjuster spro...

Page 64: ...l 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 PSI 690 kPa and make the necessary adjustments to the flow controls on the bottom of the air cylinders Adjust...

Page 65: ... cabinet covers using the 5 32 hex wrench by removing the four screws holding each cover in place 2 Using the grease gun lubricate each grease fitting with one squirt of high temperature grease There is a fitting on each of the main roll bearings pull roll bearings and on all five idlers on the control side of the machine 3 Lubricate the chain using a soft cloth and automotive oil 4 Close the cabi...

Page 66: ...ORCA III Operation Manual Maintenance and Troubleshooting GBC Pro Tech 1997 October 4 9 6FKHPDWLF LDJUDP ...

Page 67: ...Maintenance and Troubleshooting ORCA III Operation Manual GBC Pro Tech 1997 October 4 2 3QHXPDWLF LDJUDP ...

Page 68: ...em Waves on only one side of the output Hints Check nip settings Check for even paper tension Other Common Problems 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 Make sure main roll temperatures are the same Adjust cooling fans Problem Longitudinal waves or stutte...

Page 69: ...Maintenance and Troubleshooting ORCA III Operation Manual GBC Pro Tech 1997 October 4 10 Blank page ...

Page 70: ...his 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 CAUTION Unauthorized customer alterations will void this warranty THE WARRANTY MADE HEREIN IS IN...

Page 71: ...Technical Information ORCA III Operation Manual GBC Pro Tech 1997 October 5 2 Blank page ...

Page 72: ...with dual air cylinders Laminating Material Uses heat activated and pressure sensitive materials 0 55 0 140 cm wide on a 3 7 6 cm ID core Laminating Speeds 0 to 14 5 fmp 0 to 4 5 mpm Post Lamination Fanless cooling system provides uniform filtered air for thermal shock without exposure to dangerous fan blades Vinyl Transfer Complete roll to roll transfer lamination and edge trimming in one pass Sa...

Page 73: ...Technical Information ORCA III Operation Manual GBC Pro Tech 1997 October 6 2 OOXVWUDWHG 3DUWV LVW ...

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Page 108: ...brication 4 1 4 4 M Maintenance schedule 4 1 Motor 2 7 Mounting 3 7 Mounting laminating 3 7 N Nip 1 1 1 2 2 5 2 6 3 1 3 5 4 1 4 3 4 4 4 6 Nip main roll 4 5 Nip pull roll 4 6 P Photoelectric eye 1 1 2 6 3 1 Pneumatic Diagram 4 16 Power cord 2 1 Preinstallation checklist 2 1 Process control charts 3 7 Pull roll clutch Tensioning 3 1 R Riggers 1 4 2 4 2 5 Roll pressure 3 4 Roll to roll transfer 3 9 3...

Page 109: ...Index ORCA III Operation Manual GBC Pro Tech 1997 October 7 2 U Unpacking 2 4 Crate 2 4 Upper main roll 1 3 W Warnings and cautions See Safety Information Warranty 5 1 ...

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