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ORCA-I Operation Manual

ii

 GBC Pro-Tech 1997 October

The information in this publication is provided for reference and is believed to be
accurate and complete. GBC Pro-Tech is not liable for errors in this publication or for
incidental or consequential damage in connection with the furnishing or use of the
information in this publication, including, but not limited to, and implied warranty of
fitness or merchantability for any particular use.

GBC Pro-Tech reserves the right to make changes to this publication and to the
products described in it without notice. All specifications and information concerning
products are subject to change without notice.

Reference in this publication to information or products protected by copyright or
patent does not convey any license under the rights of GBC Pro-Tech or others. GBC
Pro-Tech assumes no liability arising from infringements of patents or any other rights
of third parties.

This Manual is Copyrighted © 1997 by GBC Pro-Tech. All rights reserved. The
information contained in this manual is proprietary and may not be reproduced, stored,
transmitted, or transferred, in whole or in part, in any form without the prior and
express written permission of GBC Pro-Tech.

EDNord - Istedgade 37A - 9000 Aalborg - telefon 96333500

Summary of Contents for ORCA-I

Page 1: ...he unwi nd stand s The mach ine is free of pape r scrap s wrap s and jams 8 Ther e is a pote ntial haza rd of entan glem ent in this mach ine caus ed by items such as long hair loose cloth ing and jew...

Page 2: ...ts 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 copy...

Page 3: ...ls 3 3 Front Control Panel 3 3 Rear Control Panel 3 4 Setup 3 5 Laminator Roll Pressure 3 5 Loading the Film 3 5 Positioning the Film 3 5 Heating 3 6 Paper Tips 3 6 Laminating 51 55 Materials 3 6 Proc...

Page 4: ...CHART 3 5 3 19 PROCESS CONTROL CHART 3 6 3 21 PROCESS CONTROL CHART 3 7 3 23 6HFWLRQ 0DLQWHQDQFH DQG 7URXEOHVKRRWLQJ Cleaning 4 1 Adjusting the Nip 4 3 Chain Tensioning 4 4 Adjusting the Air Cylinder...

Page 5: ...essure on the top roll is capable of producing forces greater than 1000 pounds 454kg This force is applied to any object presented in the opening called the nip between the two rolls Use care in lower...

Page 6: ...can start the machin e while you are working on or within the machin e 6 Never change or defeat the function of electric al interloc ks or other machin e shutdo wn switche s 7 Before starting this mac...

Page 7: ...d WARNING Always use care in lowering the top laminating roll You can be crushed or burned WARNING Do not operate the laminator near water You can be severely shocked electrocuted or cause a fire DANG...

Page 8: ...than a flat level surface without trained and qualified riggers You can be crushed or seriously injured The ORCA I Laminator is a large and heavy piece of equipment It is necessary to employ LICENSED...

Page 9: ...ltage points or short out parts You can be severely shocked electrocuted or cause a fire CAUTION Do not block infrared temperature sensors Main rolls could be damaged from overheating ALWAYS USE GOOD...

Page 10: ...ng and jewelry Make sure your clothing and hair fit closely to your body and that all jewelry rings and watches are removed 1994 HCS Inc 800 748 0241 Reorder No 7002 PT SAFETY INSTRUCTIONS SICHERHEITS...

Page 11: ...e 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 is blowing direc...

Page 12: ...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 GBC Pro Tech suggests that the b...

Page 13: ...2m Work Table on Wheels Table Height 37 37 1 2 94 95m 37 94 m 8 6 1 2 2 6m 8 6 1 2 2 6m Rear Front 20 6m 4 x 6 1 22m x 2m Work Table on Wheels Table Height 37 37 1 2 94 95m Electrical Supply Air Supp...

Page 14: ...ng this machine check that All persons are clear of the machine No maintenanc e work is being performed on the machine All guards are in place All parent rolls are well chucked in the unwind stands Th...

Page 15: ...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 machine...

Page 16: ...ck the front emergency stop kick cable The rolls should stop turning and raise if they are lowered If the main roll UP DOWN switch is in the UP position the machine is reset once tension is released f...

Page 17: ...electric eye system is overridden and your fingers can get caught in the nip You can be crushed or burned The ORCA I Laminator has a steel cabinet that is bolted closed to isolate the electrical and d...

Page 18: ...nd burn haza rd Stay clea r of mov ing rolle rs Stop mac hine and raise roll befo re clea ning WA RN ING AC HT UN G MISE EN GAR DE 1994 HCS Inc 800 748 0241 Reorder No 1033R PT Crus h and burn haza rd...

Page 19: ...r for the top laminating roll on or off 3 LOWER HEAT ON OFF Turns the heater controller in the bottom laminating roll on or off 4 MAIN ROLL AIR PRESSURE GAUGE Displays the air pressure pushing the mai...

Page 20: ...DISPLAY Measures and displays the air pressure driving the pull roll clutch which sets web tension 2 PULL ROLL UP DOWN Sets the pull roll to the up load or down operate position 3 FOOTSWITCH CONTINUO...

Page 21: ...me for both the top and the bottom unwinds There are two important points to remember when loading film 1 The adhesive side of the film must be oriented away on the outside from the laminating roll Ot...

Page 22: ...prints from the rear for a quick change over between hot and cold laminating 3DSHU 7LSV Always feed prints perpendicular to the laminating rolls DPLQDWLQJ 0DWHULDOV When installing or moving 51 55 rol...

Page 23: ...completed process control charts included in this section are based on Orca Film and typical prints 0RXQWLQJ 2QO 6HWXS 1 See process charts 3 1 and diagram 3 1a 2 Shims Set to the thickness of the mat...

Page 24: ...unting 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...

Page 25: ...Pressure psi kPa Top Heater On Off Top Temp Set F C Bottom Heater On Off Bottom Temp Set Main Roll Shim Dials Pull Roll Clutch On Off Pull Roll Clutch Pressure psi kPa Pull Roll Up Down Pull Roll Pres...

Page 26: ...Pull Roll Upper Main Roll Process Control Diagram Lower Main Roll Rewind Upper Film Unwind Brake Tension Lower Film Unwind Paper Unwind Stationary Idler Main Roll Shim Setting Pull Roll Shim Setting R...

Page 27: ...40 psi 275 kPa Top Heater On Off On Top Temp Set 240 F 115 C Bottom Heater On Off Off Bottom Temp Set Main Roll Shim Dials Set to board thickness Pull Roll Clutch On Off Pull Roll Clutch Pressure psi...

Page 28: ...Setting For Board Thickness Hot Upper Main Roll One Pass Mounting Process Control Diagram 3 1a Lower Main Roll Upper Pull Roll Lower Pull Roll Contact Release Paper Print Tape Front Edge of Print to B...

Page 29: ...a Top Heater On Off On Top Temp Set 240 F 115 C Bottom Heater On Off Off Bottom Temp Set Main Roll Shim Dials Set to Board Thickness Pull Roll Clutch On Off Pull Roll Clutch Pressure Pull Roll Up Down...

Page 30: ...ting For Board Thickness Hot Upper Main Roll One Pass Mount and Laminate Process Control Diagram 3 2a Upper Film Unwind Print Adhesive Coated Board Tape Front Edge of Print to Board Lower Main Roll Up...

Page 31: ...Off On Top Temp Set 220 F 104 C Bottom Heater On Off On Bottom Temp Set 220 F 104 C Main Roll Shim Dials 0 Pull Roll Clutch On Off On Pull Roll Clutch Pressure 80 psi 550 kPa Pull Roll Up Down Down Pu...

Page 32: ...er Main Roll Encapsulation Process Control Diagram 3 3a Hot Lower Main Roll Roll Feed Alternative Rewind of Finished Product Upper Film Unwind Sheet Feed Paper Unwind Lower Film Unwind Trimmed Excess...

Page 33: ...Roll Pressure 80 psi 550 kPa Top Heater On Off On Top Temp Set 225 F 107 C Bottom Heater On Off Off Bottom Temp Set Main Roll Shim Dials 0 Pull Roll Clutch On Off On Pull Roll Clutch Pressure 80 psi...

Page 34: ...ower Pull Roll Hot Upper Main Roll Two Pass Hot Laminate Cold Mount First Pass Process Control Diagram 3 4a Rewind of Finished Product Laminate Cold Lower Main Roll Roll Feed Alternative Sheet Feed Mo...

Page 35: ...ll Up Down Up Main Roll Pressure Top Heater On Off Top Temp Set Bottom Heater On Off Bottom Temp Set Main Roll Shim Dials Pull Roll Clutch On Off On Pull Roll Clutch Pressure 80 psi 550 kPa Pull Roll...

Page 36: ...s Hold Onto Liner Board As It Is Going Through Rolls Tack Leading Edge to Board Release Liner Upper Pull Roll Lower Pull Roll Raise Main Roll If Hot If Cold Use For Mounting Two Pass Hot Laminate and...

Page 37: ...in Roll Pressure 80 psi 550 kPa Top Heater On Off On Top Temp Set 110 F 45 C Bottom Heater On Off Off Bottom Temp Set Main Roll Shim Dials Pull Roll Clutch On Off On Pull Roll Clutch Pressure 80 psi 5...

Page 38: ...Lower Pull Roll Hot Upper Main Roll Two Pass Cold Mount Cold Laminate First Pass Process Control Diagram 3 6a Rewind of Finished Product Cold Lower Main Roll Roll Feed Alternative Sheet Feed Mount Ad...

Page 39: ...l Up Down Up Main Roll Pressure Top Heater On Off Off Top Temp Set Bottom Heater On Off Off Bottom Temp Set Main Roll Shim Dials Pull Roll Clutch On Off On Pull Roll Clutch Pressure 80 psi 550 kPa Pul...

Page 40: ...ess Hold Onto Liner Board As It Is Going Through Rolls Tack Leading Edge to Board Release Liner Upper Pull Roll Lower Pull Roll Raise Main Roll If Hot If Cold Use for Mounting Two Pass Cold Mount Cold...

Page 41: ...t the air cylinder rates Every Six Months Lubricate the grease fittings and chain Check wire termination tightness OHDQLQJ Tools required Adhesive coated board 80 isopropyl alcohol Rubber cement erase...

Page 42: ...UTION Use only 80 isopropyl alcohol or a rubber cement eraser to clean the laminating rolls Harsh chemicals like toluene acetone or MEK destroy the silicone covering of the rolls 4 With the laminator...

Page 43: ...n the upper black lock collar located at the top of the cylinder shaft on the control side of the laminator 3 16 1 8 Set Screw Lock Collar Shim Dial Figure 4 1 Adjusting the Nip 4 Turn the lock collar...

Page 44: ...t the rolls contact properly 9 Spin both lock collars down until they are just touching the shim disks The disks should not be able to move up or down when each collar is tight 10 Tighten the set scre...

Page 45: ...at there is to play in the secondary chain GMXVWLQJ WKH LU OLQGHU 5DWH If the top main roll or top pull roll move up or down unevenly the air cylinder flow controls need to be adjusted To adjust the a...

Page 46: ...ight is sufficient 3 Rotate the upper main air cylinder adjustment knobs out 3 turns Rotate the lower main air cylinder adjustment knobs out 2 turns 4 As with the main rolls the pull roll should rise...

Page 47: ...grease gun lubricate each grease fitting shown in Figure 4 4 with one squirt of high temperature grease 1994 HCS Inc 800 748 0 241 Reorder No 1012 PT Mo vin g par ts can cru sh and cut Do not ope rat...

Page 48: ...parts and technical service North America 1 800 790 7787 Europe 44 0 1844 202 440 or fax 44 0 1844 202 441 Please provide serial number when calling for service For film and application questions Nort...

Page 49: ...f 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 enca...

Page 50: ...Maintenance and Troubleshooting ORCA I Operation Manual GBC Pro Tech 1997 October 4 10 Blank page EDNord Istedgade 37A 9000 Aalborg telefon 96333500...

Page 51: ...contact the rollers neglecting to clean the laminator overheating the rolls and failure caused by adhesives or improper use of the machine Warranty repair or replacement does not extend the warranty b...

Page 52: ...Warranty ORCA I Operation Manual GBC Pro Tech 1997 October 5 2 Blank page EDNord Istedgade 37A 9000 Aalborg telefon 96333500...

Page 53: ...e 10 25 4 cm maximum diameter Laminating Speeds 0 to 14 fmp o to 4 3 mpm with variable speed reversible action start and stop controlled either through the instrument panel or with the footswitch Enca...

Page 54: ...Technical Information ORCA I Operation Manual GBC Pro Tech 1997 October 6 2 Blank page EDNord Istedgade 37A 9000 Aalborg telefon 96333500...

Page 55: ...minating rolls 6 1 Laminating speeds 6 1 Lubrication 4 1 M Main rolls 4 3 Maintenance schedule 4 1 Motor 2 6 N Nip 1 1 2 5 2 6 3 1 4 1 4 3 6 1 Main roll adjusting 4 3 O Outfeed slitters 6 1 Outfeed ta...

Page 56: ...l GBC Pro Tech 1997 October 7 2 U Unpacking 2 4 Crate 2 4 Upper main roll 4 3 Upper pull roll 4 4 V Vacuum table 6 1 W Warnings and cautions See Safety Information Warranty 5 1 EDNord Istedgade 37A 90...

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