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Applications

Orca 1600 Operation and Maintenance Manual

© GBC Films Group February 2001

Diagram - 4

H O T

C O L D

P rin t

T h e rm a l film

P S A m o u n t

a d h e s ive

O u tp u t

F in is h e d

p ro d u c t

re w in d

( o p tio n a l )

P S A m o u n t

a d h e s ive

R o ll o f p rin ts

( ro ll to ro ll o p tio n )

Summary of Contents for Orca 1600

Page 1: ...son Road DeForest WI 53532 Revision A Ph 608 246 8844 Fx 608 246 8645 ORCA 1600 OPERATION MAINTENANCE MANUAL February 2001 GBC Films Group Do not duplicate without written permission Part number 930 061 ORCA 1600 GBC Pro Tech ...

Page 2: ... Group assumes no liability arising from infringements of patents or any other rights of third parties This publication is copyrighted 2000 by GBC Films Group All rights reserved The information contained in this publication is proprietary and may not be reproduced stored transmitted or transferred in whole or in part in any form without the prior and express written permission of GBC Films Group ...

Page 3: ...Read me file Orca 1600 Operation and Maintenance Manual GBC Films Group February 2001 This page intentionally left blank ...

Page 4: ...February 2001 Fax Correspondence Fax number 608 246 8645 Date To Sean Flood at GBC Pro Tech 4151 Anderson Road DeForest WI 53532 From Company Address Phone number Fax number Re Orca 1600 Operations and Maintenance Manual 930061 Section Page Correction s Additional comments ...

Page 5: ...Read me file Orca 1600 Operation and Maintenance Manual GBC Films Group February 2001 This page intentionally left blank ...

Page 6: ...n 1 0 Safety 1 1 Symbols 1 1 1 2 Pneumatic safety 1 2 1 3 Safety features 1 2 1 4 Mechanical safety 1 4 1 5 Heating safety 1 4 1 6 Maintenance safety 1 5 1 7 Installation 1 5 1 8 Operation 1 8 1 9 Applications 1 10 1 10 Troubleshooting 1 12 1 11 Maintenance 1 12 1 12 Label Explanation 1 14 Figure 1 12 1 Label Location 1 16 ...

Page 7: ...ty 2 1 Limited warranty information 2 1 2 2 Exclusions to the warranty 2 1 Section 3 0 Specifications 3 1 General 3 1 3 2 Consumables 3 2 3 3 Function 3 3 3 4 Electrical 3 4 3 5 Dimensions 3 5 Section 4 0 Installation 4 1 Pre installation check list 4 1 Figure 4 1 1 Suggested floor layout 4 3 4 2 Know your machine 4 4 ...

Page 8: ...Unpacking 4 5 4 4 Shrink wrap 4 5 4 5 Crated 4 6 4 6 Accessory pack 4 9 4 7 Electrical connection 4 9 4 8 Air connection 4 11 4 9 Installing levelers 4 12 4 10 Leveling 4 13 4 11 Calibrations 4 14 Section 5 0 Operations 5 1 Power ON OFF 5 1 5 2 Front control panel 5 2 Figure 5 2 1 Front control panel 5 4 ...

Page 9: ...Rear control panel 5 7 5 4 Setting temperature 5 8 5 5 In case of an emergency 5 9 5 6 Film loading unloading 5 10 5 7 Main roller nip 5 11 5 8 Pull roller nip 5 12 5 9 Shutdown procedure 5 12 Section 6 0 Applications 6 1 Temperature chart 6 1 6 2 Helpful hints 6 2 6 3 Temp conversion chart 6 3 Figure 6 3 1 Temperature conversion chart 6 4 ...

Page 10: ...ms 6 5 Chart 0 blank chart 6 6 Diagram 0 6 7 Chart 1 1 pass mounting 6 8 Diagram 1 6 9 Chart 2 PSA decaling 6 10 Diagram 2 6 11 Chart 3 Mounting a PSA decal 6 12 Diagram 3 6 13 Chart 4 Thermal decal 6 14 Diagram 4 6 15 Chart 5 Mounting a thermal decal 6 16 Diagram 5 6 17 Chart 6 Thermal encapsulation 6 18 Diagram 6 6 19 ...

Page 11: ...1 Wave problems 7 1 7 2 Film problems 7 3 7 3 Machine problems 7 4 7 4 Glossary 7 5 Section 8 0 Maintenance 8 1 Maintenance schedule 8 1 8 2 Cleaning the rollers 8 2 8 3 Dust Pre coated boards 8 3 8 4 Dirt and PSA adhesive Alcohol and cloth 8 3 8 5 Thermal adhesive 8 4 8 6 Clean the laminator 8 5 8 7 Clean the control panels 8 6 ...

Page 12: ...MATION Indicates helpful information that should be considered before during or after an action step or procedure is given 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 W ARNING Indicates a potentially hazardous situation which if not avoid...

Page 13: ...d on the rear control panel This switch controls the up and down motion of the top pull roller Before pressing either of these switches to the DOWN position ensure that nothing is in the nip ar eas If any problem or danger should occur depress ing any of the emergency stop push buttons or engag ing the emergency cables described in Section 1 3 stops the rollers from closing and raises them com ple...

Page 14: ... sensitive or too loose Contact your local service representative for this adjustment PHOTO EYE The Orca 1600 is equipped with three sets of PHOTO EYEs one at the main roller nip one behind the pull roller nip and one in front of the pull roller nip The PHOTO EYEs when blocked by an object stop the rollers from turning and will resume turning when the sensor is no longer blocked This safety featur...

Page 15: ...rom the ends of the removable idlers when removing or installing them at various locations on the machine 1 5 Heating safety The heating components of the Orca 1600 can reach temperatures of over 200 o F 100 o C DANGER At these temperatures there is a danger of severe burn if the rolls are touched during setup operation or servicing In the event of a run away heat failure the machine is equipped w...

Page 16: ...ed and qualified to GBC Films Group standards to fulfill that job This person will have completed and passed the full service training course from GBC Films Group Any GBC Technician GBC Specialist and or GBC Films Group Technician that has been through the GBC Pro Tech service training course 1 7 Installation The following symbols are positioned at various points in Section 4 Installation CAUTION ...

Page 17: ...ms if applicable make note of this on the Bill of Lading WARNING The unpacking process requires at least two people You can be severely injured crushed or cause damage to the laminator INFORMATION Depending on the destination and customer preference your machine may be shipped in various ways The laminator may arrive shrink wrapped or in a plywood crate on a skid Please follow the unpacking proced...

Page 18: ...re not secured to the pallet Ensure the pallet is on a flat even surface before attempting to roll the machine off About recycling The crate components can be reused for shipping the laminator again or can be disassembled and the wood and screws recycled The shrink wrap is not recyclable so it must be discarded INFORMATION Ensure sufficient space for opening of the cabinets for maintenance and ser...

Page 19: ...ICAL SHO CK These calibrations require the laminator to be powered up while the cabinets are opened 1 8 Operation The following symbols are positioned at various points in Section 5 Operation WARNING Do not wear ties loose fit clothing or dangling jewelry while operating or servicing the laminator These items can get caught in the nip and choke you or you can be crushed or burned W ARNING When the...

Page 20: ...y in the up position until the emergency stop feature is deactivated INFO RM ATIO N The motor must be engaged for the cooling fans to turn on If the fan switch is in the on position the fans will automatically turn on when the motor is engaged INFO RM ATIO N INFO RM ATIO N When requiring top and bottom heat it is recommended to set both temperatures to the same set point The maximum set point temp...

Page 21: ...g symbols are positioned at various points in Section 6 Applications WARNING Do not wear ties loose fit clothing or dangling jewelry while operating or servicing the laminator These items can get caught in the nip and choke you or you can be crushed or burned For optimal temperature settings of various laminates contact your supplier or sales representative INFO RM ATIO N General rule Smaller prin...

Page 22: ... experience complications with this application INFO RM ATIO N Excessive pressure will cause the substrate to bow or flatten INFO RM ATIO N Excessive brake tension may cause the image to curl Always use the minimum amount of brake for the job INFO RM ATIO N CAUTIO N Excess pressure can damage the laminating rollers Always use the minimum roll pressure necessary to complete the task Never stop the ...

Page 23: ...servicing the laminator These items can get caught in the nip and choke you or you can be crushed or burned 1 11 Maintenance The following symbols are positioned at various points in Section 8 Maintenance WARNING Do not wear ties loose fit clothing or dangling jewelry while operating or servicing the laminator These items can get caught in the nip and choke you or you can be crushed or burned INFO...

Page 24: ...xcessive pressure can destroy the silicone layer by pressing to hard or scrubbing too long in one spot Keep the terry cloth towel kind of damp to make the rubbing of the roller smooth INFO RM ATIO N CLEANING HEATED ROLLERS CAN IGNITE THE FUMES CAUTIO N CAUTIO N Do NOT pick or pull heat activated adhesive off the rolls when they are cold You can cause irreparable damage to the laminating rolls ELEC...

Page 25: ...binets This machine is to be serviced only by trained and authorized personnel W ARNING ACHT UNG M ISE EN GARDE Crush and burn hazard Stay clear of m oving rollers Stop m achine and raise roll before cleaning Roller Pinch Point Keep hands and fingers away You may be crushed and or burned W AR NIN G AC HT U N G M ISE EN G AR DE M oving parts can crush and cut Moving Parts Keep hands and fingers awa...

Page 26: ...king on or within the m achine 6 Never change or defeat the function of electrical interlocks or other m achine shutdown switches 7 Before starting this m achine check that All persons are clear of the m achine No m aintenance work is being perform ed on the m achine All guards are in place All parent rolls are well chucked in the unwind stands T he m achine is free of paper scraps wraps and jam s...

Page 27: ... e a r of th e m a chi ne N o m a inte na nce w ork is b e ing pe r form e d o n the m a chine A ll gua rds a re in p la ce A ll pa re nt rolls a re w e ll ch ucke d in the u nw ind sta nds T he m a ch ine is fr e e of pa pe r scra p s w ra ps a n d ja m s 8 Th e re is po te ntia l h a za rd o f e nta gle m e nt in this m a c hine ca use d by ite m s suc h a s lo ng ha ir loose clo thing a nd je w...

Page 28: ...ification incorrectlinevoltage fire accident flood or other hazard 2 1 Limited Warranty Thiswarrantyspecificallydoesnotcoverdamage 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 initialoneyearperiodfromthedateofdelivery CAUTION Unauthorized ...

Page 29: ...e Qualified Any engineerthathasexperiencewithelectrical and mechanical design of lamination equipment The engineers should be fully aware of all aspects of safety withregardstolaminationequipment Anycommissioningorserviceengineermustbe of competent nature trained and qualified to GBC Pro Tech standards to fulfill that job This person will have completedandpassedthefullservicetrainingcoursefrom GBC...

Page 30: ...rintunwind Two rewinds 1 upper front 1 lower rear center Infeed and oufeed tables Pressure plate Footswitch Bi directionaloperations Four emergency stop push buttons E STOPs Front and rear emergency cables E CABLEs Photo electric nip sensors Independent top and bottom heater units Two fixed web tension idlers 1 lower 1 upper Three repositionable web idlers No slip core grip chucks 2 per unwind Spe...

Page 31: ...tubes Pressuresensitivelaminates Pressuresensitiveadhesives Lowmeltlaminates Thermallaminates Thermaladhesives Up to a 10 in roll diameter 25 4 cm 3 in core standard 7 62 cm 64 in maximum pressure sensitive 163 cm 62 in maximum thermal 158 cm 63 in maximum paper width 160 cm Up to 1 in thick 2 54 cm either direction Designed to UL CSA CE safety standards 3 in diameter x 66 3 8 in length 7 62 x 168...

Page 32: ...s Roll design 0 15 ft min 0 4 6 m min 2 1 4 horse power drive motor Bi directional D C motor 68o F 270o F 20o C 132o C Front control panel Rear control panel Footswitch Independent Cal 3200 control units Heat capable upper and lower main rollers Drivenlowermainroller Freespinninguppermainroller Pneumaticcontroledlowerpullroller Freespinningupperpullroller Highreleasesiliconerollers ...

Page 33: ...ltage used A C voltage used AIR Compressorrequirements 230 240 VAC 50 60 Hz single phase 55 amps 230 240 VAC Wye 3 phase 25 amps phase 34 120 B T U hour 5000 watts per heater No heat motor only 1 3 amps Top heat and motor 20 23 amps Both heat and motor 40 43 amps 24 vdc 230 vac minimum Filtered air at 2 cubic feet per minute cfm 50 liters minute at a pressure of 70 pounds per square inch psi 500 k...

Page 34: ...ebruary 2001 Section 3 5 Dimensions Weight Crated Uncrated Dimensions Crated Uncrated Nip Height 2800 lbs 1270 kg 2300 lbs 1043 kg 75 in H x 43 in W x 102 in L 191 cm H x 109 cm W x 259 cm L 60 in H x 33 in W x 82 in L 152 cm H x 84 cm W x 208 cm L Refer to Figure 3 5 1 35 1 5 in 90 cm ...

Page 35: ...Page 3 6 Specifications Orca 1600 Operation and Maintenance Manual GBC Films Group February 2001 Figure 3 5 1 Dimensions ORC A 1600 GBC Pro Tech 60 in 152 cm 82 in 208 cm 33 in 84 cm ...

Page 36: ... A work area must be established that allows for operation in both the front and rear of the laminatorandprovidesspaceforefficientmaterial flow Figure 4 1 1 illustrates a typical machine arealayout Istheenvironmentappropriateforthelaminator The laminator requires a clean dust and vapor freeenvironmenttooperateproperly Itmustnot be located where there is air blowing directly on themachine Haveyouco...

Page 37: ...ator is a large and heavy piece of equipment It is necessary to employ LICENSED RIGGERS ONLY to move the laminator The 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 You can be crushed or seriously injured For instructions on how to connect power proceed to 4 7 Electric...

Page 38: ...February 2001 Figure 4 1 1 Suggested Floor Layout 20 ft 508 cm 13 ft 330 cm 3 ft 91 cm 8 ft 8 in 220 cm 8 ft 8 in 220 cm 4 ft x 6 ft 101 6 x 152 cm W ork table on wheels Air compressor or air line drop Electrical cord drop Front Back 4 ft x 6 ft 101 6 x 152 cm W ork table on wheels ...

Page 39: ... side Drive side Rear Front Figure 4 2 2 Top view T able idler Pressure plate Front table Rear table Upper unwind M ain rollers Pull rollers Upper unwind brake Rear table bracket M ain roller shim dial Figure 4 2 3 Front view Front control panel E ST OP E C AB LE Rewind brake Leveling pad Lower unwind Middle unwind Cardboard rewind tube Motor Figure 4 2 4 Rear view Rear control panel Tie bar Unw i...

Page 40: ...on a skid Please follow the unpacking procedure that pertains to your method of shipment WARNING The unpacking process requires at least two people You can be severely injured crushed or cause damage to the laminator Withregardstoyourshippingmethod useoneof thefollowingproceduresdescribedtosafelyandproperly unwrap uncrateyourlaminator 4 4 Shrink Wrapped a Inspectthemachineforanyobviousshipping dam...

Page 41: ...shandling and or tipping GBC Films Group bears no responsibility for personal injury or damage due to moving the laminator improperly INFORMATION Tools required 2 Phillips head screwdriver 7 8 open end wrench or adjustable wrench Crow bar A second person 4 5 1 Uncrate the laminator a Remove the top of the crate and then the sides in the order shown in Figure 4 5 1 CAUTION Do not allow the top to f...

Page 42: ...o the rollers b Move all packing materials to a safe distance 4 5 3 Moving the laminator a Havethelaminatorremovedoffoftheskidoneof twomethods 1 Rolled off the skid and placed on the floor by licensedriggersusingtheincludedramps The ramps must be secured utilizing screws removed from the disassembled crate WARNING Do not attempt to use the ramps if they are not secured to the pallet Ensure the pal...

Page 43: ... for maintenance and servicing INFO RM ATIO N b Removeanyplasticstrappingand orpacking paper taped to the rollers CAUTION Do not use a knife or other sharp object to remove the shrink wrap from around the laminator You can cause irreparable damage to the rollers c Remove all packing materials to a safe distance from the laminator and dispose of properly About recycling The crate components can be ...

Page 44: ...nection The Orca 1600 laminator requires 220 240 VAC electrical power for proper operation The power supply may be either single phase or three phase five wire or four wire For single phase power a 55 amp service is required and for three phase power 25 amps per phase is required TheOrca1600requirestheelectricalpowercord tobewireddirectlytothelineterminalblocklocatedwithin the control side cabinet...

Page 45: ... 2 4 3 P T U P T U 2 A 1 A 2 3 1 1 1 1 1 1 4 3 2 1 1 2 4 6 5 2 1 2 2 1 0 3 4 9 3 2 7 8 2 4 A 1 A 2 3 1 1 1 1 1 1 4 3 2 1 1 2 4 6 5 2 1 2 2 1 0 3 4 9 3 2 7 8 2 4 A 1 A 2 3 1 1 1 1 1 1 4 3 2 1 1 2 4 6 5 2 1 2 2 1 0 3 4 9 3 2 7 8 2 4 A 1 A 2 3 1 1 1 1 1 1 4 3 2 1 1 2 4 6 5 2 1 2 2 1 0 3 4 9 3 2 7 8 2 4 A 1 A 2 3 1 1 1 1 1 1 4 3 2 1 1 2 4 6 5 2 1 2 2 1 0 3 4 9 3 2 7 8 2 4 A 1 A 2 3 1 1 1 1 1 1 4 3 2 1...

Page 46: ...ntact a qualified electrician to replace the cord 4 8 Air connection Thelaminatorrequiresfilteredairat2cubicfeet per minute cfm 50 liters minute at a pressure of 70 pounds per square inch psi 500 kPa The air supply must be clean free of dirt and dry Moisture causes corrosionandparticlescanblockthepneumaticcontrols Eitherproblemcancausethelaminatortomalfunction It is the customer s responsibility t...

Page 47: ...omer option If you choose not to level the laminator and you encounter output problems please level the machine and try your application again before calling for technical support Restingthelaminatoron thelevelingpadswillpreventthe machinefromrollingduringsetup operationorservicing Tools required 1 1 2 in open end wrench 1 7 8 in open end wrench Fourlevelingpads from the accessory pack a Be sure t...

Page 48: ...he leveler is centered 1 2 in W rench Center the bubble b Place the leveler on the lower front tie bar and levelthemachinefromlefttoright ORCA 1600 GBC P ro T ech Place level here c Place the leveler on the control side frame not thetopofthecabinet andlevelthemachinefrom front to rear ORCA 1600 GBC Pro Tech Place level here e Do the same for the drive side ORCA 1600 GBC P ro Tech Place level here ...

Page 49: ...Improper calibrations can result in poor laminationoutput ELECTRICAL SHO CK These calibrations require the laminator to be powered up while the cabinets are opened a The main roller nip is to be calibrated b The pull roller nip is to be calibrated c All three photo eyes are to be calibrated d The drive chains are to be checked and tensionedifnecessary e Air rate on both set of rollers are to be ch...

Page 50: ...n roller nip how to set the pull roller nip and how to properly shutdown the laminator W ARNING When the laminator rollers are in motion keep hands and fingers away from the nip of the rollers You may be CRUSHED or BURNED The laminator will only turn on if all E STOPs are unlatched INFO RM ATIO N 5 1 Power on off ELECTRICAL SHO CK Do not turn power on if the power cord is damaged or frayed You can...

Page 51: ...s showing rate or linear footage total R 0 0 SEL RST 2 Speed Control Dial Adjusts the speed of the motor from zero to a maximum speed of 15 feet per minute 4 5 meters per minute Turn the dial clockwise to increase speed and counter clockwise to reduce speed 3 Forward Reverse Switch determines the motor direction In the FWD position the motor will turn in a forward motion In the REV position the mo...

Page 52: ...oll to on I or off O HEAT TOP BOTTOM 9 Main Roll Pressure Adjustment Adjusts the air pressure supplied to the main roller air cylinders Pull out on the knob to turn and push in on the knob to lock down When decreasing pressure allow the pressure guage to drop below the desired value then increase pressure to the set pressure desired This allows for a more accurate pressure reading INFO RM ATIO N 1...

Page 53: ...O TECH ENGINEERING DEFOREST W I U S A 608 246 8844 MOTOR CONTROLS LAMINATOR ROLL CONTROLS MAIN POW ER R 0 0 SEL RST FW D REV AUTO STOP SPEED PRESSURE ROLL ADJ 10 20 30 40 50 60 70 80 90 100 0 P S I CAL 3200 68 CAL 3200 68 HEAT TOP BOTTOM 1 2 3 4 6 5 8 7 10 9 11 12 Figure 5 2 1 Front control panel ...

Page 54: ...e to the set pressure desired This allows for a more accurate pressure reading INFO RM ATIO N 2 Clutch Pressure Gauge Displays the air pressure supplied to the pneumatic clutch 3 Clutch on off Switch Engages or disengages air flow to the pneumatic clutch driving the lower pull roller The lower pull roller is connected to the chain drive system via a pneumatic clutch When the clutch switch is on I ...

Page 55: ...IO N 8 0 PRESSU RE ROLL 10 20 30 40 50 60 70 90 100 0 P S I ADJ 80 7 Cooling Fans on off Switch Turns the cooling fans on or off The cooling fans only operate when the motor circuit is engaged CO OLING FANS The motor must be engaged for the cooling fans to turn on If the fan switch is in the on position the fans will automatically turn on when the motor is engaged INFO RM ATIO N 8 Auto Stop Switch...

Page 56: ... Manual GBC Films Group February 2001 ADJ PULL ROLL CLUTCH PRESSURE 8 0 PRESSURE PULL ROLL CONTROLS COOLING FANS ROLL AUTO STOP 10 20 30 40 50 60 70 80 90 100 0 P S I 10 20 30 40 50 60 70 90 100 0 P S I ADJ 80 1 2 3 5 6 4 7 8 Figure 5 3 1 Rear control panel ...

Page 57: ... point temperature is 270 o F 132 o C INFO RM ATIO N b Once the desired set point is displayed release both buttons c Decrease main roller pressure lower the upper main roller set a slow speed and press AUTO to allow the rollers to roll for an even heating surface Decrease a Press and hold the asterisk key while pressing the down key until the desired set point is displayed on the temperature cont...

Page 58: ...P buttons or press using your foot on either E CABLE in the event of an emergency situation Push E M E R G E N C Y S T O P When a safety feature is engaged the upper rollers raise and power to the drive motor is removed INFO RM ATIO N b Resolve the emergency situation c If an E STOP was depressed turn the knob counter clockwise to disengage the E STOP button If an E CABLE was pressed continue with...

Page 59: ... roll of film a Adjust the core chucks to fit within the roll of film being used The roll of film should be approximately center of the main rollers The core chucks should be close to the edge of the roll of film Roll of film Core chuck Core chuck Core support b Pull up on the clevis pin to the unwind support saddle you are about to load a roll of film to Clevis pin Unw ind support saddle c Swing ...

Page 60: ...nd arm back into its unwind support saddle and push the clevis pin down If not follow the Load a roll of film procedure again from step d 5 7 Main roller nip To set the main roller nip for use with substrates can easily be obtained by setting the shim dials on the main roller to the desired opening a Ensure the upper main roller is in the up position The nip can only be changed with the upper roll...

Page 61: ...ust pull roller pressure for the desired setting with respect to the substrate being used d Press the pull roller UP DOWN switch to DOWN on the rear control panel 5 9 Shutdown procedure Perform the steps below to properly shutdown your machine a Unweb the laminator and clean the rollers as described in Section 8 2 Cleaning the rollers b Set the left and right shim dials of the main roller to great...

Page 62: ...d choke you or you can be crushed or burned Theprocesscontrolchartsandwebdiagrams illustrated in this section are reference points only Parameters will vary with regards to laminate thickness laminate widths laminate types print types ink or toner types paper types environment conditions and operator experience 6 1 Temperature chart Thetemperaturechartisonlyastartingpointfor generaltypesoflaminate...

Page 63: ...ng MountingontheOrca1600canbeachievedfrom thefrontoperatingpositionusingthemainrollersorfrom therearoperatingpositionusingthepullrollers Heatcan also assist with mounting it follows the same hints as pressuresensitivematerials The mount adhesive must not exceed 1 in the width of the substrate If it does you will experience complications with this application INFO RM ATIO N Pressure Most lamination...

Page 64: ...e for the job INFO RM ATIO N General CAUTIO N Excess pressure can damage the laminating rollers Always use the minimum roll pressure necessary to complete the task Never stop the laminator when an image is within the nip of either set of rollers INFO RM ATIO N Laminates and papers should always be stored in a controlled enviroment INFO RM ATIO N 6 3 Temp conversion chart Atemperatureconversionchar...

Page 65: ...9 76 1 170 76 7 171 77 2 172 77 8 173 78 3 174 78 9 175 79 4 176 80 177 80 6 178 81 1 179 81 7 180 82 2 181 82 8 182 83 3 183 83 9 184 84 4 185 85 186 85 6 187 86 1 188 86 7 189 87 2 190 87 8 191 88 3 192 88 9 193 89 4 194 90 195 90 6 196 91 1 197 91 7 198 92 2 199 92 8 o F o C 203 95 204 95 6 205 96 1 206 96 7 207 97 2 208 97 8 209 98 3 210 98 9 211 99 4 212 100 213 100 6 214 101 1 215 101 7 216 ...

Page 66: ...up and operation Thissectioncontainsablankprocesscontrolchart and diagram for the ORCA 1600 as well as completed charts for the basic operations of the laminator The pro cess control charts should be kept in this manual or in a book close to the laminator The Orca 1600 laminators respond in a very ac curate and repeatable manner The charts provide a way to set up each time every time for repeatabl...

Page 67: ...ANEL SETTING S Speed ft m in Roller direction FW D REV M ain roller position UP DO W N M ain roller shim M ain roller pressure Top heater pow er O N O FF Bottom heater pow er O N O FF Top heater tem perature Bottom heater tem perature REAR CO NTRO L PANEL SETTING S Pull roller clutch O N O FF Pull roller position UP DO W N Pull roller pressure Cooling fans O N O FF Pull roller clutch pressure Pull...

Page 68: ...Page 6 7 Applications Orca 1600 Operation and Maintenance Manual GBC Films Group February 2001 Diagram 0 ...

Page 69: ...ater pow er O N O FF Top heater tem perature 230 240 o F 110 115 o C Bottom heater tem perature 32 o F 0 o C REAR CONTRO L PANEL SETTINGS Pull roller clutch O N O FF Pull roller position UP DOW N Pull roller pressure N A Cooling fans O N O FF Pull roller clutch pressure N A Pull roller shim N A Com m ents RELATED DIAG RAM Reference diagram Diagram 1 If you are using a heat sensitive print position...

Page 70: ...Page 6 9 Applications Orca 1600 Operation and Maintenance Manual GBC Films Group February 2001 Diagram 1 HO T CO LD Release liner Print Therm al m ount Substrate ...

Page 71: ...ater tem perature 120 o F 49 o C Bottom heater tem perature 32 o F 0 o C REAR CONTRO L PANEL SETTINGS Pull roller clutch O N O FF Pull roller position UP DOW N Pull roller pressure 80 psi Cooling fans O N O FF Pull roller clutch pressure 80 psi Pull roller shim 0 nip Com m ents RELATED DIAG RAM Reference diagram Diagram 2 Even though it is PSA film heat w ill assist the bonding and flow of adhesiv...

Page 72: ...eration and Maintenance Manual GBC Films Group February 2001 Diagram 2 W ARM CO LD Release liner Print PSA film PSA m ount adhesive O utput Finished product rew ind optional optional PSA m ount adhesive Roll of prints roll to roll option ...

Page 73: ...eater pow er O N O FF Bottom heater pow er O N O FF Top heater tem perature 120 o F 49 o C Bottom heater tem perature 32 o F 0 o C REAR CONTRO L PANEL SETTINGS Pull roller clutch O N O FF Pull roller position UP DOW N Pull roller pressure N A Cooling fans O N O FF Pull roller clutch pressure N A Pull roller shim N A Com m ents RELATED DIAG RAM Reference diagram Diagram 3 Using a little heat w ill ...

Page 74: ...Page 6 13 Applications Orca 1600 Operation and Maintenance Manual GBC Films Group February 2001 Diagram 3 W ARM CO LD Release liner Decal Substrate Hold decal here ...

Page 75: ...pow er O N O FF Top heater tem perature 220 225 o F 105 107 o C Bottom heater tem perature 32 o F 0 o C REAR CONTRO L PANEL SETTINGS Pull roller clutch O N O FF Pull roller position UP DOW N Pull roller pressure 80 psi Cooling fans O N O FF Pull roller clutch pressure 80 psi Pull roller shim 0 nip Com m ents RELATED DIAG RAM Reference diagram Diagram 4 If using other than a 3 m il therm al film us...

Page 76: ...0 Operation and Maintenance Manual GBC Films Group February 2001 Diagram 4 HO T CO LD Print T herm al film PSA m ount adhesive O utput Finished product rew ind optional optional PSA m ount adhesive Roll of prints roll to roll option ...

Page 77: ... roller pressure N A Top heater pow er O N O FF Bottom heater pow er O N O FF Top heater tem perature 32 o F 0 o C Bottom heater tem perature 32 o F 0 o C REAR CONTRO L PANEL SETTINGS Pull roller clutch O N O FF Pull roller position UP DOW N Pull roller pressure 20 40 psi Cooling fans O N O FF Pull roller clutch pressure 80 psi Pull roller shim Thickness of substrate Com m ents RELATED DIAG RAM Re...

Page 78: ...Page 6 17 Applications Orca 1600 Operation and Maintenance Manual GBC Films Group February 2001 Diagram 5 HO T CO LD Release liner Decal Substrate Hold decal here ...

Page 79: ... er O N O FF Top heater tem perature 220 225 o F 105 107 o C Bottom heater tem perature 220 225 o F 105 107 o C REAR CONTRO L PANEL SETTINGS Pull roller clutch O N O FF Pull roller position UP DOW N Pull roller pressure 80 psi Cooling fans O N O FF Pull roller clutch pressure 80 psi Pull roller shim 0 nip Com m ents RELATED DIAG RAM Reference diagram Diagram 6 If using other than a 3 m il therm al...

Page 80: ...ca 1600 Operation and Maintenance Manual GBC Films Group February 2001 Diagram 6 HO T HO T Print T herm al film T herm al film O utput Finished product rew ind optional optional T herm al film Roll of prints roll to roll option ...

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Page 82: ... to correct your typical output typeproblems Usetheeasytofollowguideforassistance 7 1 Wave problems Thefollowingisalistofcommonoutputwave problemsyoumayencounter Thearrowalongthelengthoftheoutput represents the direction of feed travel INFORMATION For optimal temperature settings of various laminates contact your supplier or sales representative Problem Dwavesintheimagebutnotinthelaminate Hints Ch...

Page 83: ...t Hints Check the nip setting of main rollers Check the nip setting of pull rollers Check for even paper tension Problem Angled waves in the output on both sides Hints Checkforinsufficientmainrollerpressure Checkforinsufficientpullrollerpressure Checkthemainrollernipsettings Checkthepullrollernipsettings Problem Indentwavesinoutputafterthepullrollers Hints Insufficientcoolingtime Allowoutputtocool...

Page 84: ...mperature Problem Delamination Hints Check operating temperatures Check operating speed Laminatecompatibilitywithink Inkcompatibilitywithpaper 7 2 2 Pressure sensitive Problem Silveringinthelaminate Hints Add 100 120o F 37 49o C to the temperature Increasepressuretolaminatingrollers Problem Tunnelinginfinishedproduct Hints Print should be wound image side out Donotrolltightly Do not roll at all Pr...

Page 85: ...elf WARNING Do not wear ties loose fitting clothing or dangling jewelry while operating or servicing the laminator These items can get caught in the nip and choke you or you can be crushed or burned Problem Nocontrolpanelfunctions Hints Ensure an E STOP has not been pushed down Reset the main roller UP DOWN switch Confirm that the MAIN POWER is to the ON position Be sure power is supplied to the l...

Page 86: ...onthatisappliedtothelaminatedmaterial betweenthemainandpullrolls Thistensionisappliedby having the pull rolls turn faster than the main rolls and then having some form of clutching or torque limiting applied to the pull rolls This tension is important for maintainingasmoothflatfinishedimage Coiling A term used to describe an image rolling up on itself This is caused by differences in the brake ten...

Page 87: ...perform the actual lamination They are rolls capable of being heated in thermalrolllaminatorsandareusuallylargerindiameter thanthepullrolls Media Termusedtodescribethematerialsusedtoprint an image i e the papers inks toners etc Mount adhesive A term used to describe a two sided pressure sensitive adhesive used in mounting images to various substrates Thismaterialcancomewithoneortworelease liners a...

Page 88: ...ond surface A term to denote the back side of a substrate Commonly referenced when discussing front mounted images to a clear substrate with an optically clear mount adhesive Silvering A term used to describe one of two occurrences 1 airbubblestrappedbetweentheproductandathermal laminate generallycausedbyinsufficientheatbeingapplied bythelaminatoror2 theadhesiveisnotfullyactivatedin a pressure sen...

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Page 90: ...OCK Remove power from the laminator before servicing You can be severely shocked electrocuted or cause a fire 8 1 Maintenance Schedule Below is a recommended maintenance schedule Before performing any of the steps listed read through the procedures first Please follow the instructions pertaining to the step you are performing INFORMATION Daily Clean the rollers See cleaning in this section Inspect...

Page 91: ...mpletedandpassedthefullservicetrainingcoursefrom GBCFilmsGroup AnyGBCTechnician GBCSpecialist and or GBC Films Group Technician that has been through the GBC Pro Tech service training course 8 2 Cleaning the rollers Tools required Adhesive coated boards picks up dust and particles off of the rolls Protective rubber gloves Thiswillprotectyourhandsfromtheisopropyl alcohol 80 isopropyl alcohol amildd...

Page 92: ...switch run the adhesive coated boards through the rollers f Perform steps d and e again g Do this as many times as needed to clean the laminatorrolls 8 4 Dirt and PSA adhesive Alcohol and cloth a Allowthelaminatortocoolslightlytonohigher than 110o F 43 o C CAL 3200 110 CAL 3200 110 CLEANING HEATED ROLLERS CAN IGNITE THE FUMES CAUTIO N b SetthemachinedirectiontoFWDwhencleaning thepullrollers Setthe...

Page 93: ... of the roller smooth INFO RM ATIO N f Use the footswitch to rotate the roller to a new spot to clean g Do this as many times as needed to clean the laminatorrolls 8 5 Thermal adhesive a Allowthelaminatortocoolslightly nohigher than 110o F 43 o C CAL 3200 110 CAL 3200 110 CLEANING HEATED ROLLERS CAN IGNITE THE FUMES CAUTIO N b SetthemachinedirectiontoFWDwhencleaning thepullrollers Setthemachinedir...

Page 94: ...sure can destroy the silicone layer by pressing to hard or scrubbing too long in one spot c Wipe away the beads with isopropyl alcohol and a cotton terry cloth 8 6 Clean the laminator ELECTRICAL SHOCK Remove power from the laminator before cleaning You can be severely shocked electrocuted or cause a fire a Use a damp cotton terry cloth water only cleantheexteriorofthelaminator b If water is not st...

Page 95: ...tor before cleaning You can be severely shocked electrocuted or cause a fire a Use a terry cloth towel to wipe he control panels ELECTRICAL SHOCK Do not use liquid or aerosol cleaners on the laminator Do not spill liquid of any kind on the laminator You can be severely shocked electrocuted or cause a fire Use only a damp cloth for cleaning unless other wise specified ...

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