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Maintenance

Orca III/ Orca III T Operation and Maintenance Manual

© GBC Films Group February 2001

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Summary of Contents for ORCA III T

Page 1: ...t WI 53532 Revision Ph 608 246 8844 Fx 608 246 8645 ORCA III ORCA III T OPERATION MAINTENANCE MANUAL February 2001 GBC Films Group Do not duplicate without written permission Part number 930 062 ORCA III T GBC Pro Tech ORCA III GBC Pro Tech ...

Page 2: ...Films 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 G...

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Page 4: ...ary 2001 Fax Correspondence Fax number 608 246 8645 Date To Technical Coordinator at GBC Pro Tech 4151 Anderson Road DeForest WI 53532 From Company Address Phone number Fax number Re Orca III Orca III T Operations and Maintenance Manual 930062 Section Page Correction s Additional comments ...

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

Page 6: ... 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 Section 2 0 Warranty 2 1 Limited warranty information 2 1 2 2 Exclusions to the warranty 2 1 ...

Page 7: ...s 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 4 3 Unpacking 4 5 4 4 Shrink wrapped 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 ...

Page 8: ...n 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 5 5 3 Rear control panel 5 6 Figure 5 3 1 Rear control panel 5 9 5 4 Setting temperature 5 10 5 5 In case of an emergency 5 11 5 6 Film loading unloading 5 12 5 7 Main roller nip 5 14 5 8 Pull roller nip 5 14 5 9 Unwind brake tension 5 15 5 10 Rewind brake tension 5 15 5 11 Shutdown procedure 5 16 ...

Page 9: ...perature conversion chart 6 4 6 4 Charts and diagrams 6 5 Figure 6 4 1 Poly in Poly out diagrams 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 Roll to roll psa decaling 6 12 Diagram 3 6 13 Chart 4 Mounting a PSA decal Main rollers 6 14 Diagram 4 6 15 Chart 5 Mounting a PSA decal Pull rollers 6 16 Diagram 5 6 17 ...

Page 10: ...6 23 Chart 9 PSA encapsulation Main rollers 6 24 Diagram 9 6 25 Chart 10 Roll to roll PSA encapsulation 6 26 Diagram 10 6 27 Chart 11 PSA encapsulation Pull rollers 6 28 Diagram 11 6 29 Chart 12 Vinyl transfer with trimming 6 30 Diagram 12 6 31 Chart 13 Vinyl transfer no trimming 6 32 Diagram 13 6 33 Chart 14 Over lamination of transferred vinyl images 6 34 Diagram 14 6 35 Chart 15 Roll to roll vi...

Page 11: ... 7 3 7 2 2 Pressure sensitive 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 8 8 Chain tensioning 8 6 8 9 Lubrication 8 7 Figure 8 9 1 Grease fitting poin...

Page 12: ...bols INFORMATION 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...

Page 13: ...ocated 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 co...

Page 14: ... sensitive or too loose Contact your local service representative for this adjustment PHOTO EYE The Orca III Orca III T 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 saf...

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 III Orca III T 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 ...

Page 16: ...trained 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 CAU...

Page 17: ... items 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 pr...

Page 18: ...hey are 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 an...

Page 19: ...LECTRICAL 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 Whe...

Page 20: ...y stay 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...

Page 21: ...itioned at various points in Section 6 Applications Because the Orca III T has an upper Teflon coated roller your results may vary when doing an encapsulation process INFO RM ATIO N T M 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...

Page 22: ... in the width of the substrate If it does you will 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 press...

Page 23: ...g or 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...

Page 24: ...O N Excessive 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...

Page 25: ...n these cabinets 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 f...

Page 26: ...g 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 8 ...

Page 27: ...re cl 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...

Page 28: ...ormodification 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 Unauthor...

Page 29: ...achine 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 completedandpassedthefullservicetrainingcoursefro...

Page 30: ...ront 1 upper rear 1 lower front and 1 lower rear Infeed and oufeed tables Footswitch Bi directionaloperations Four emergency stop push buttons E STOPs Front and rear emergency cables E CABLEs Photo electric nip sensors PHOTO EYEs Independent top and bottom heater units Two fixed web tension idlers 1 lower 1 upper Five repositionable web idlers Two removable slitter idlers 1 front 1 rear Two remova...

Page 31: ...wind tubes Pressuresensitivelaminates Pressuresensitiveadhesives Lowmeltlaminates Thermallaminates Thermaladhesives Up to a 10 in roll diameter 25 4 cm 3 in core standard 7 62 cm 58 in maximum pressure sensitive 147 cm 55 in maximum thermal 140 cm 55 in maximum paper width 140 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 ...

Page 32: ... ft min 0 4 6 m min 1 4 horse power drive motor Bi directional D C motor 32o F 290o F 0o C 143o C Front control panel Rear control panel Footswitch Independent Cal 3200 control units Heat capable upper and lower main rollers Drivenlowermainroller Freespinninguppermainroller Pneumaticcontrolledlowerpullroller Freespinningupperpullroller Highreleasesiliconerollers Teflon coated Upper roller only Hig...

Page 33: ...tates and Canada Europe B T U output Heater wattages Amperagedraw D C voltage used A C voltage used 230 240 VAC 50 60 Hz single phase 55 amps 230 240 VAC Wye 3 phase 25 amps phase 37 532 B T U hour 5500 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 ...

Page 34: ...s Group February 2001 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: ...ons Orca III Orca III T Operation and Maintenance Manual GBC Films Group February 2001 Figure 3 5 1 Dimensions both machines have the same dimensions ORCA III GBC Pro Tech 82 in 208 cm 60 in 152 cm 33 in 84 cm 2 in 5 1 cm ...

Page 36: ...eroomforthelaminator 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 ...

Page 37: ...rca III T Laminator is a large and heavy piece of equipment It is necessary to employ LICENSED RIGGERS ONLY to move the laminator It 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 re alignment You can be crushed or seriously injured For instructions on how to connect power proceed to 4 7 Ele...

Page 38: ...roup 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: ...GBC Pro Tech Figure 4 2 2 Top view T able idler Sm all table Large table Rear table option Upper unwind Main rollers Pull rollers Upper unwind brake Rear table bracket Main roller shim dial Figure 4 2 3 Front view Front control panel E ST O P E CABLE Rew ind brake Leveling pad Front low er unw ind Middle unw ind Cardboard rew ind tube Motor Figure 4 2 4 Rear view R ear control panel T ie bar U nw ...

Page 40: ... 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 damag...

Page 41: ...to mishandling 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...

Page 42: ...age to 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 th...

Page 43: ...nets 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 INFO RM ATIO N About recycling The crate...

Page 44: ...items listed above contact your local service technician or sales representative 4 7 Electrical Connection The Orca III Orca III T 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 The Orca I...

Page 45: ...wrench 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 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...

Page 46: ...rician to replace the cord 4 8 Air connection Thelaminatorrequiresfilteredairat2cubicfeet per minute cfm 50 liters minute at a pressure of 100 pounds per square inch psi 700 kPa The air supply must be clean free of dirt and dry Moisture causes corrosionandparticlescanblockthepneumaticcontrols Eitherproblemcancausethelaminatortomalfunction It is the customer s responsibility to provide appropriate ...

Page 47: ...alling levelers Leveling of the machine is a customer 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 4 l...

Page 48: ... the leveler is centered 1 2 in w rench C e n t e rt h eb u b b l e b Place the leveler on the lower front tie bar and levelthemachinefromlefttoright ORCA III GBC Pro Tech Place level here c Place the leveler on the control side frame not thetopofthecabinet andlevelthemachinefrom front to rear ORCA III GBC P ro Tech Place level here e Do the same for the drive side ORCA III GBC Pro Tech Place leve...

Page 49: ...ill overhang the brake slighlty CAUTIO N Caution should always be exercised when using a knife Sharp knife can cut you c Use a knife or razor to trim the excess brake pad from the brake Brake pad Trim excess d Save the center piece from the brake pad for use later in Section 4 12 Slitter assemblies e Remove the rewind tube f Remove the O Ring from the rewind drive puck Rew ind drive puck O R ing R...

Page 50: ...1 4 in allen wrench from the allen wrench set in the accessory pack The center piece from the brake pad step d in Section 4 11 Unwind rewind brake a Cutthecenterpieceofthebrakepadasillustarted below 1 2 3 4 b Place the pieces 1 2 3 4 on the slitter idler standoffsasillustratedbelow Stand offs Pieces of cut pad c Use the 1 4 allen wrnech to secure two slitter assemblies to the front tie bar below t...

Page 51: ... in the proper rest position Unsecured blade can cut you 4 13 Calibrations The following calibrations should be performed byaqualifiedGBCtechnicianbeforethemachineistobe operated These calibrations may not be performed by the operator 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...

Page 52: ... to set the pull roller nip unwind brake tension rewind brake tension 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...

Page 53: ...otal The RST button will reset the linear footage total whether the display is 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 FW D REV AUTO STOP SPEED 3 Forward Reverse Switch determines the ...

Page 54: ...n roller to on I or off O HEAT TO P BOTTOM Top and bottom temperature control units on off switches must be in the ON I position to heat either roller INFO RM ATIO N 8 Bottom Heater on off Switch Turns the temperature controller unit for the lower main roller to on I or off O HEAT TOP BO TTO M Top and bottom temperature control units on off switches must be in the ON I position to heat either roll...

Page 55: ...o the up position the upper main roller raises PRESSURE RO LL ADJ 10 20 30 40 50 60 70 80 90 100 0 P S I 12 Main Power Indicator Light When illuminated there is electrical power going to the machine M AIN PO WER FAN TABLE 13 Fan Table ON OFF Switch This switch controls the optional vacuum table When pressed to the I position the fans on the vacuum table turn on When pressed to the 0 position the f...

Page 56: ...re 5 2 1 Front control panel PRO 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 32 CAL 3200 32 HEAT TOP BOTTOM 1 2 3 4 6 5 8 7 10 9 11 12 FAN TABLE 13 ...

Page 57: ... 50 60 70 80 90 100 0 P S I 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 2 Clutch Pressure Gauge Displays the air pressure supplied to the pneumatic clutch ADJ PRESSURE 10 20 30 40 50 60 70 80 90 100 0 P S I 3 Clutch on off Switch Engages or diseng...

Page 58: ...e Gauge Displays the air pressure supplied to the pull roller air cylinders 80 PRESSURE RO LL 10 20 30 40 50 60 70 90 100 0 P S I ADJ 80 6 Pull Roller UP DOWN Switch Signals the solenoid air valve for the pull roller air cylinders to shift to the appropriate position to either raise or lower the upper pull roller 80 PRESSURE RO LL 10 20 30 40 50 60 70 90 100 0 P S I ADJ 80 When an emergency stop f...

Page 59: ...hen the motor is engaged INFO RM ATIO N 8 Auto Stop Switch This switch will engage the motor circuitry and disengage the motor circuitry This is a momentary switch for latching purposes so that two separate switches can serve the same function See Front Control Panel for the other location of this switch CO O LING FANS AUTO STO P For a complete illustration of the front control panel refer to Figu...

Page 60: ...nance Manual GBC Films Group February 2001 Figure 5 3 1 Rear control panel 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 ...

Page 61: ...um set point temperature is 290 o F 143 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 temperatur...

Page 62: ...TOP 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 wi...

Page 63: ...ace of the rollers Therm al Poly out Therm al Poly in PSA Poly out PSA Poly in M ount adhesiv e only Load a 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 t...

Page 64: ...aligns with the lower roll of film by measuring the distance from the same side frame to the edge of the roll Unloading a roll of film a Cut the laminate from the web CAUTIO N Do not use an open blade to cut the web near the rollers You can put cuts into the rollers b Pull up on the clevis pin c Swing the unwind shaft out away from the laminator Upper unw ind shaft show n for illustration purposes...

Page 65: ...Adjust main roller pressure for the desired setting with respect to the substrate being used d Press the main roller UP DOWN switch to DOWN 5 8 Pull roller nip To set the pull roller nip for use with substrates can easily be obtained by setting the shim dials on the pull roller to the desired opening a Ensure the upper pull roller is in the up position The nip can only be changed with the upper ro...

Page 66: ...se decrease b Turn the black brake knob counter clockwise to decrease unwind brake tension 5 10 Rewind brake tension The rewind brakes control the tension of the rewind tubes Rewind brakes along with the unwind brakes allow for precise control of the release liner in PSA films If using the rewind s in a roll to roll application the rewind brakes are helpful as the finished product rewind becomes h...

Page 67: ...rs as described in Section 8 2 Cleaning the rollers b Set the left and right shim dials of the main roller to greater than 1 2 inch 1 27 cm This will prevent the main rollers from contacting if the air should be removed INFO RM ATIO N c Set the pull roller shim disk to 1 2 inch This will prevent the pull rollers from contacting if the air should be removed INFO RM ATIO N d Turn the power ON OFF sw...

Page 68: ...G 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 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...

Page 69: ...Mounting Mounting on the Orca III Orca III T can be achievedfromthefrontoperatingpositionusingthemain rollers or from the rear operating position using the pull rollers Heatcanalsoassistwithmounting itfollowsthe samehintsaspressuresensitivematerials 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 P...

Page 70: ...essure 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 General rule Smaller prints require more speed or less temperature Larger prints require less speed or more...

Page 71: ... 6 169 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...

Page 72: ... should be kept in this manual or in a book close to the laminator The Orca III Orca III T laminators respond in a very accurate and repeatable manner The charts pro vide a way to set up each time every time for repeatable performance by assuring that all controls are set to opti mum The completed process control charts included in this section are based on GBC films GBC boards and typical prints ...

Page 73: ... CO NTRO L PANEL SETTING S Speed ft m in Roller direction FW D REV M ain roller position UP DOW 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 CONTRO L PANEL SETTINGS Pull roller clutch O N O FF Pull roller position UP DOW N Pull roller pressure Cooling fans O N O FF Pull roller clutch press...

Page 74: ...7 Applications Orca III Orca III T Operation and Maintenance Manual GBC Films Group February 2001 Diagram 0 Cooling tube Permanent idler Removable idler Slitter Idler Table Idler Tie bar Legend Slitters Rewind ...

Page 75: ...F Bottom heater 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 pri...

Page 76: ...Page 6 9 Applications Orca III Orca III T Operation and Maintenance Manual GBC Films Group February 2001 Diagram 1 Print Liner Therm al m ount Substrate Hot Cold ...

Page 77: ... 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 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 ...

Page 78: ...a III Orca III T Operation and Maintenance Manual GBC Films Group February 2001 Diagram 2 Print Finished product M ount adhesive M ount adhesive option M ount adhesive option PSA Lam inate Liner W arm Cold O ver the idler option ...

Page 79: ... 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 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 3 Even though it is PSA film heat w ill assist the bonding and f...

Page 80: ...and Maintenance Manual GBC Films Group February 2001 Diagram 3 Finished product M ount adhesive M ount adhesive option PSA Lam inate Liner W arm Cold O ver the idler option Roll of prints im age in im age out Infeed slitting option Output slitting option ...

Page 81: ...heater 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 4 Using a little heat w ill...

Page 82: ...Page 6 15 Applications Orca III Orca III T Operation and Maintenance Manual GBC Films Group February 2001 Diagram 4 Substrate W arm Cold Release liner Apply pressure here Decal ...

Page 83: ...tom 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 Substrate thickness Com m ents RELATED DIAG RAM Reference diagram Diagram 5 Using the pull rollers to m ...

Page 84: ...Page 6 17 Applications Orca III Orca III T Operation and Maintenance Manual GBC Films Group February 2001 Diagram 5 Substrate Hot Hot Release liner Apply preesure here Decal ...

Page 85: ...tom heater 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 6 If using other than a 3 m il therm...

Page 86: ...ca III Orca III T Operation and Maintenance Manual GBC Films Group February 2001 Diagram 6 Print Finished product M ount adhesive M ount adhesive option M ount adhesive option Therm al Lam inate Hot Cold O ver the idler option ...

Page 87: ...heater pow 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 CO NTRO L PANEL SETTING S Pull roller clutch O N O FF Pull roller position UP DO W 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 7 If using other than a 3 ...

Page 88: ...II Orca III T Operation and Maintenance Manual GBC Films Group February 2001 Diagram 7 Print Finished product Therm al lam inate Therm al lam inate option Therm al Lam inate Hot Hot O ver the idler option Therm al lam inate option ...

Page 89: ... er O N O FF Bottom heater pow 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 8 If usin...

Page 90: ...nd Maintenance Manual GBC Films Group February 2001 Diagram 8 Finished product Therm al lam inate Hot Hot O ver the idler option Roll of prints im age in im age out Infeed slitting option Output slitting option Therm al lam inate Therm al lam inate option ...

Page 91: ...N O FF Top heater tem perature 120 o F 49 o C Bottom heater tem perature 120 o F 49 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 9 Even though it is PSA film heat w ill assist the bonding and ...

Page 92: ...ations Orca III Orca III T Operation and Maintenance Manual GBC Films Group February 2001 Diagram 9 Print Finished product PSA lam inate PSA lam inate option PSA lam inate Liner W arm W arm O ver the idler option Liner ...

Page 93: ...er pow er O N O FF Top heater tem perature 120 o F 49 o C Bottom heater tem perature 120 o F 49 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 10 Even though it is PSA film heat w ill assist the...

Page 94: ...Orca III T Operation and Maintenance Manual GBC Films Group February 2001 Diagram 10 Finished product PSA lam inate PSA lam inate option PSA lam inate Liner W arm W arm O ver the idler option Liner Roll of prints im age in im age out ...

Page 95: ...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 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 11 Use this process if the m ain rollers are too hot above 150 oF o...

Page 96: ...Page 6 29 Applications Orca III Orca III T Operation and Maintenance Manual GBC Films Group February 2001 Diagram 11 Hot Hot PSA lam inate PSA lam inate Liner Liner PSA lam inate option Finished product ...

Page 97: ...INGS 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 40 60 psi Pull roller shim 0 nip Com m ents RELATED DIAG RAM Reference diagram Diagram 12 Orca III 1 3 ft m in 30 91 cm m in Orca III T 4 6 ft m in 122 183 cm m in Speeds and tem perature vary betw een the O rca III and Orca III T due to the different type of...

Page 98: ... 31 Applications Orca III Orca III T Operation and Maintenance Manual GBC Films Group February 2001 Diagram 12 Finished product Vinyl Vinyl option Trim take up Hot Cold Roll of transfer im ages Paper take up ...

Page 99: ...ll 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 40 60 psi Pull roller shim 0 nip Com m ents RELATED DIAG RAM Reference diagram Diagram 13 Orca III 3 5 ft m in 91 152 cm m in Orca III T 6 8 ft m in 183 244 cm m in Speeds and tem perature vary betw een the O rca III and Orca III T due to the different type of upper...

Page 100: ...Page 6 33 Applications Orca III Orca III T Operation and Maintenance Manual GBC Films Group February 2001 Diagram 13 Finished product Vinyl Vinyl option Hot Cold Roll of transfer im ages Paper take up ...

Page 101: ... roller shim N A M ain 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 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 ...

Page 102: ...Page 6 35 Applications Orca III Orca III T Operation and Maintenance Manual GBC Films Group February 2001 Diagram 14 Hot Hot Vinyl over lam inate Liner T ransferred im ages Finished product ...

Page 103: ...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 40 60 psi Pull roller shim 0 nip Com m ents RELATED DIAG RAM Reference diagram Diagram 15 Orca III 1 3 ft m in 30 91 cm m in Orca III T 4 6 ft m in 122 183 cm m in Speeds and tem p vary betw een the O rca III and Orca III T due to the ...

Page 104: ... Applications Orca III Orca III T Operation and Maintenance Manual GBC Films Group February 2001 Diagram 15 Finished product Vinyl Vinyl option Trim take up Hot Cold Roll of transfer im ages Paper take up Liner ...

Page 105: ...Page 6 38 GBC Films Group February 2001 Applications Orca III Orca III T Operation and Maintenance Manual This page intentionally left blank ...

Page 106: ... attempt 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 ...

Page 107: ...tput 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 Check for insufficient main roller pressure Checkforinsufficientpullrollerpressure Checkthemainrollernipsettings Checkthepullrollernipsettings Problem Indentwavesinoutputafterthepullrollers Hints Insufficientcoolingtime Allowoutp...

Page 108: ...inate Hints Decrease the speed Increase the operating temperature 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 wou...

Page 109: ...NG 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 laminator ...

Page 110: ...hetensionthatisappliedtothelaminatedmaterial 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 br...

Page 111: ...that 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 lin...

Page 112: ...mage Second 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 pres...

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Page 114: ... SHOCK 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 Insp...

Page 115: ... have completedandpassedthefullservicetrainingcoursefrom 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 alcoho...

Page 116: ... footswitch 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 S...

Page 117: ...bbing 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 Setthemachi...

Page 118: ... pressure 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 n...

Page 119: ...mp cloth for cleaning unless other wise specified 8 8 Chain tensioning If the motor should stall stutter or if the chain makes a popping snapping sound check the chain for propertensioning Whenthechainisproperlytensioned you should see approximately 1 4 inch 0 64 cm of slack on each side of the longest stretch of the chain ELECTRICAL SHO CK Remove power from the laminator before performing any mai...

Page 120: ...inch 0 64 cm play to each side Prim ary Adjustable Idler Place Pry Bar Here e Tighten the nut with the 1 1 8 inch socket or wrench INFO RM ATIO N Use a the 3 8 inch wrench on the SO1 shaft as you tighten the nut if the shaft begins to turn f Next youmustresettheselftensioningidler Use a 10 inch adjustable wrench on the base and turnthepivotarmagainstthechain g Aligning the arrow on the pivot arm t...

Page 121: ...ench or socket 8 9 Lubrication Bearingsshouldbegreasedonceeverysixmonths Slide spots should be cleaned and lubricated at the same time Whengreasingthebearings onlyshootoneshotof greasefromagreasegunintoeachgreasefitting ELECTRICAL SHO CK Remove power from the laminator before performing any maintenance procedures Tools required 5 32 allen wrench Hightemperaturebearinggrease Whitelithiumgrease Grea...

Page 122: ...ca III T Operation and Maintenance Manual GBC Films Group February 2001 Figure 8 9 1 Grease fitting points Control side Bottom Pull Roll Drive side 11 12 1 6 5 4 3 2 D rive Side C ontrol Side B ottom M ain Roll 10 9 Top M ain Roll 8 7 ...

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