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Maintenance and Troubleshooting

ORCA-IV Image Transfer Laminator Operation Manual

4-10

© GBC Pro-Tech 1998 October

17

I pressed the pull roll up
push button, but the rolls did
not go up!

a.

Is there air pressure to the
machine?

b. Is the machine reset?

a.

Verify that the air supply is suffi-
cient (

≤

100 psi).

b. Reset the machine. See "Machine

Reset Procedure" on page 3-3.

18

I pressed the top roll temper-
ature control “ON” push but-
ton and nothing happens.

a.

Are the e-stop push buttons
pressed and the kick cables reset?

b. Is the machine reset?
c.

Is there a decimal point in the dis-
play?

a.

See problem 12.

b. Reset the machine. See "Machine

Reset Procedure" on page 3-3.

c.

Reset the machine. See "Machine
Reset Procedure" on page 3-3.

19

The display shows unusual
numbers or characters.

a.

Is the machine reset?

a.

Reset the machine. See "Machine
Reset Procedure" on page 3-3.

20

I press the preheater push
button and a “P” is displayed
on the control panel.

a.

This is normal. This shows that
you are in PREHEAT AUTO
mode.

a.

If you press the preheat button
again, it will go off.

21

I pressed the cooling fan
push button and the fan did
not turn off.

a.

Is the cooling fan toggle switch
set correctly?

a.

The cooling fan push button is a
4-way toggle switch, keep push-
ing the button until the fan goes
off. From the off position, press
once to turn only the cooling idler
on, press twice to turn the cooling
tubes only on, press a third time
to turn on both the cooling idler
and the cooling tubes, and press a
fourth time to turn the cooling
systems off.

22

I pressed the cooling fan
push button and the fan did
not turn ON.

a.

Are the e-stop push buttons
pressed and the kick cables reset?

b. Is the machine reset?

a.

See problem 12.

b. Reset the machine. See "Machine

Reset Procedure" on page 3-3.

23

I pushed the totalizer push
button, the display changed
to read 4 characters, but the
value does not increase.

a.

Is the proximity switch that reads
the motor sensor teeth adjusted
properly?

b. Does the input light “X1” come

on when the proximity switch
comes on?

a.

Make adjustment and try again.

b. If the input light comes on, go to

problem 48.

24

I pressed the totalizer-reset
push button while in total-
izer mode, and it did not
reset and other buttons on
the panel do not work either.

a.

Is the machine reset?

a.

Reset the machine. See "Machine
Reset Procedure" on page 3-3.

Problem

Number

Problem

Possible Cause

Corrective Action

«
...
46
47
48
49
50
...
»

Summary of Contents for ORCA-IV

Page 1: ... 40 30 20 10 100 90 80 70 60 50 40 30 20 10 100 90 80 70 60 50 40 30 20 10 PRO TECH 100 90 80 70 60 50 40 30 20 10 1 2 3 4 0 0 0 0 CAL 3200 psi 100 90 80 70 60 50 40 30 20 10 kPa 700 630 560 490 420 350 280 210 140 70 CAL 3200 4 N O T A U S E M E R GENCY ST O P A R R E T D U R G E N C E N O T A U S E M E R GENCY ST O P A R R E T D U R G E N C E SA FE TY INST RU CT IONS SICH ER HE ITS RICH TL INIEN...

Page 2: ...s 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...

Page 3: ... 4 Front Clutch Brake Panel 3 6 Rear Control Panel 3 8 Rear Clutch Brake Panel 3 10 Setup 3 11 Loading the Film 3 11 Heating 3 11 Recommended Materials 3 12 Films Excluding Vinyl Transfer and Overlamination 3 12 Vinyl Transfer and Overlamination Materials 3 12 Setting the Slitter 3 12 Paper Tips 3 12 Positioning the Film and Centering the Web 3 13 Film Spacing 3 14 Operational Tips and Tricks 3 14...

Page 4: ...October 6HFWLRQ 0DLQWHQDQFH DQG 7URXEOHVKRRWLQJ Cleaning 4 1 Lubrication 4 3 Adjusting the Kick Cable 4 3 Contacting Technical Support 4 4 Output Troubleshooting Guide 4 6 6HFWLRQ DUUDQW Limited Warranty 5 1 Exclusions to the Warranty 5 1 6HFWLRQ 6SHFLILFDWLRQV 6HFWLRQ QGH ...

Page 5: ...epressing any of the emergency buttons stops the rolls from closing and raises them completely Note To quickly stop the machine in the event of an emer gency press any of the emergency stop buttons or apply force to either kick cable This action stops the machine completely and raises the rolls In addition the rolls of the ORCA IV can reach tem peratures of over 290 F 143 C At these tempera tures ...

Page 6: ...the laminator 100 90 80 70 60 50 40 30 20 10 100 90 80 70 60 50 40 30 20 10 100 90 80 70 60 50 40 30 20 10 PRO TE CH 100 90 80 70 60 50 40 30 20 10 1 2 3 4 0 0 0 0 CAL 3200 psi 100 90 80 70 60 50 40 30 20 10 kPa 700 630 560 490 420 350 280 210 140 70 CAL 3200 4 N O T A U S E M E R GENCY STO P A R R E T D U R G E N C E N O T A U S E M E R GENCY STO P A R R E T D U R G E N C E 1994 HCS Inc 800 748 0...

Page 7: ...ase the speed Note If the display does not have a decimal point in it the machine needs to be reset Figure 1 4 Machine Reset Button Despite the safety features built into the ORCA IV extreme caution must be used when operating or ser vicing the unit READ THE FOLLOWING WARN INGS AND CAUTIONS BEFORE ATTEMPTING TO OPERATE OR SERVICE THE ORCA IV IMAGE TRANSFER LAMINATOR WARNING IMPORTANT Kick Cable Re...

Page 8: ...leaning the rolls with 80 or stronger isopropyl alcohol Use only in a well ventilated area Wear rubber gloves Use only on cool rolls Cleaning heated rolls can ignite the fumes Raise the upper main roll when the image transfer laminator is not in operation Prolonged contact can damage the rolls Do not leave the top roll heater on with the roll raised Heat builds up in a stationary roll and can dama...

Page 9: ...ct alignment of the rolling parts of the machine and requires extensive realignment GBC Pro Tech s warranty does not cover malfunction of the equipment due to mishandling and or tipping GBC Pro Tech bears no responsibility for personal injury or damage due to moving the image transfer laminator improperly Only a qualified electrician should connect power to the image transfer laminator You can be ...

Page 10: ... Exterior Panels 100 PSI 700 KPa 1997 HCS Inc 800 748 0241 No 6101 52BVPK Em erg en cy Sto p Kic k Ca ble s Lo cat ed Be low Kic k or Ste p on to Sto p La mi na tin g Pro ces s Located On Door HIGH LEAKAGE CURRENT Earth connection essential before connecting supply Located Inside Cabinet Located Inside Cabinet CAUTION FOR CONTINUED PROTECTION AGAINST RISK OF FIRE REPLACE ONLY WITH SAME TYPE AND RA...

Page 11: ...ng and jewelry Make sure your clothing and hair fit closely to your body and that all jewelry rings and watches are removed Decal Meaning Decal Meaning or WARNING ACHTUNG MISE EN GARDE WARNING ACHTUNG MISE EN GARDE or 100 PSI 700 KPa 1997 HCS Inc 800 748 0241 No 6101 52BVPK CAUTION Rolls are heavy Use proper lifting techniques to prevent injury CAUTION Air pressure must be less than 100 PSI 700 kP...

Page 12: ...Safety ORCA IV Image Transfer Laminator Operation Manual 1 8 GBC Pro Tech 1998 October Blank page ...

Page 13: ...ioned office area with forced 10 make up air However the image transfer lam inator must not be located where there is air blow ing directly on it Major fluctuation in temperature and humidity are to be avoided IMPORTANT IMPORTANT Have you contacted a certified electrician to both hard wire the laminator and ensure that an adequate power supply having the appropriate capacity overcurrent protection...

Page 14: ...block pneumatic controls Either problem can cause the laminator to malfunction It is the customer s responsibility to provide appro priate filters and water traps for the air hose before the air is routed to the laminator Pro Tech suggests that the best approach to the air requirement is to provide a dedicated small compressor for the lami nator A standard light duty to horse power 1 kW electric a...

Page 15: ... 1998 October 2 3 Figure 2 6 Machine Space Requirements 24 7 3m 20 6m 4 x 6 1 2m x 2m Work Table on Wheels 153 3 89m 85 2 16m Front Rear 50 1 27m 38 4 98m Electrical Supply Standard Inlet on Bottom of Machine Air Supply On Bottom of Machine 4 x 6 1 2m x 2m Work Table on Wheels ...

Page 16: ...wrenches 1 4 2 Web unwind spacers 10 Remove any plastic strapping and packing paper taped to the rolls IMPORTANT 11 Remove all packing materials to a safe distance from the image transfer laminator 12 Level the machine using the procedure included in this section Do not attempt to move the image transfer laminator across anything other than a flat level surface without trained and qualified rigger...

Page 17: ...1 8 hex wrench Adjustable wrench Setup Procedure 1 Inspect the machine for any obvious shipping dam age 2 Remove the drive and control side cabinet covers with the 1 8 hex wrench by removing the screws securing the covers to the machine Lift the covers off 3 Inspect all the bolts and tighten any that were loos ened during shipping 4 Have a certified electrician wire the machine directly to a power...

Page 18: ... down on one of the emergency stop buttons The image transfer laminator should stop immedi ately Reset the button by turning it clockwise until it pops up Press the reset button See Figure 1 4 Machine Reset Button to locate the main machine reset button Start the laminator The machine should resume operation Always check all four buttons IMPORTANT Are the emergency stop kick cables working With th...

Page 19: ...t you are operating the machine in reverse Are the heaters working Verify that the heater controller heats the top roll The bottom roll cannot be heated Is the temperature set correctly Check that the temperature is set to 290 F 143 3 C for most transfer processes IMPORTANT CAUTION Once you have completed the startup checklist you can safely run a test sample Never operate the image transfer lamin...

Page 20: ...Installation ORCA IV Image Transfer Laminator Operation Manual 2 8 GBC Pro Tech 1998 October Blank page ...

Page 21: ... of the top laminator roll Before pressing this switch to the DOWN position ensure that nothing is in the nip area If any problem or danger should occur depressing any of the emergency buttons stops the rolls from closing and raises them completely Note To quickly stop the machine in the event of an emer gency press any of the emergency stop buttons or apply force to either kick cable This action ...

Page 22: ... the laminator 100 90 80 70 60 50 40 30 20 10 100 90 80 70 60 50 40 30 20 10 100 90 80 70 60 50 40 30 20 10 PRO TE CH 100 90 80 70 60 50 40 30 20 10 1 2 3 4 0 0 0 0 CAL 3200 psi 100 90 80 70 60 50 40 30 20 10 kPa 700 630 560 490 420 350 280 210 140 70 CAL 3200 4 N O T A U S E M E R GENCY STO P A R R E T D U R G E N C E N O T A U S E M E R GENCY STO P A R R E T D U R G E N C E 1994 HCS Inc 800 748 ...

Page 23: ...e the speed Figure 3 4 Machine Reset Button XGLEOH 6LJQDOV For your safety the machine has several audible signals that are used to alert you to the status of the machine The following table lists the alert signals Table 3 1 Audible Signals Kick Cable Reset Button Audible Signal Meaning Continuous rapid beep If the roll is down but not turning the machine will begin beeping con tinuously after 10 ...

Page 24: ...ntil you change it The computer will not override your setting or change the display 6 SPEED ACCUMULATOR DISPLAY Dis plays either the accumulator or speed depending on which you have selected with the SPEED ACCUMULATOR TOGGLE A letter in the dis play before the speed readout indicates the mode of operation H Manual mode with the preheater off P Automatic mode with the preheater on L Manual mode wi...

Page 25: ...he cooling fan on or off Push once to turn only the cooling idlers on push again to turn only the cooling tubes on push a third time to turn both cooling idlers and cooling tubes on and push a fourth time for all cooling off 12 PREHEATER AIR TEMPERATURE optional Provides a readout of the temperature of the air inside the preheater and the set point for the desired temperature 13 PREHEATER HEAT ON ...

Page 26: ... FRONT CLUTCH REWIND INDI CATOR Indicates that this set of controls is for the upper front clutch 7 MIDDLE FRONT BRAKE PERCENT WEB FORCE Indicates the web force tension for this brake as a percentage of the total possible tension the brake can exert What the pressure indicator displays changes depending upon whether the motor is on or off and what mode you are operating the machine under With the ...

Page 27: ...d the machine in Automatic Tension mode the indicator displays the material web ten sion you set Once the motor arrow is pressed and the machine starts the computer calculates the appropriate pressure to attain the required web force based on the roll size The indicator then changes to read the actual air pressure in psi sent to the clutch brake If the machine is in Manual Tension mode the indicat...

Page 28: ... to machine status 0 The machine is reset and ready to be started 8888 Main power has just been turned on and the main reset has not yet been pressed In addition to these codes if an emergency stop button or kick cable is activated the decimal point will no longer be displayed for example 3 0 would change to 3 0 Simply resetting the emergency stop button or kick cable does not change the display Y...

Page 29: ...GBC Pro Tech 1998 October 3 9 12 ACCUMULATOR RESET Resets the accumu lator 13 SPEED ACCUMULATOR TOGGLE Toggles control between the speed and the accumulator 14 MOTION CONTROL FORWARD STOP REVERSE Controls the direction of the drive system forward reverse or stop ...

Page 30: ...perates when the pull roll is down 5 MIDDLE REAR CLUTCH PRESSURE Adjusts the clutch pressure up or down 6 MIDDLE REAR CLUTCH INDICATOR Indi cates that this set of controls is for the middle rear clutch 7 LOWER REAR CLUTCH PERCENT WEB FORCE Indicates the web force tension for this clutch as a percentage of the total possible tension the clutch can exert What the pressure indicator displays changes ...

Page 31: ...eed problems wrinkles and other assorted troubles will occur See Table 3 2 for centering and alignment information IMPORTANT HDWLQJ Use the following instructions when heating the upper main roll 1 Set the heater switch to ON 2 Adjust the temperature controller for the desired operating temperature using the temperature con troller set point adjustment To adjust the set point hold the star button ...

Page 32: ...re compatibil ity and operational settings for the transfer process Consult your transfer system supplier to ensure the cor rect combinations of materials are being used 6HWWLQJ WKH 6OLWWHU 1 Turn the thumbscrew on the slitter counterclock wise until it stops Figure 3 9 Slitter 2 Turn the thumbscrew one turn clockwise 3 Set the slitter blade against the plastic covered black roll 4 Engage the slit...

Page 33: ...ct rewind For best results align one edge of the rewind core to match the material edge measurement on the unwind 9 Web the transfer paper and tape it to the front rewind as shown in the diagram If the paper is wider than the vinyl it will be necessary to use the slitters to cut the paper down to match the width of the vinyl See Setting the Slitter on page 3 12 10 Load and web the overlaminate as ...

Page 34: ...d let the old material web pull the new material through the machine To splice vinyl When splicing the vinyl stop the machine before the roll is totally used up 1 Load a new roll of vinyl on the unwind shaft and place it on the machine Engage the shaft into the drive tang 2 The old material should be left long enough to lay over the new roll This provides a straight firm surface to splice onto 3 T...

Page 35: ...d map for correct machine setup and operation This section contains a completed chart for the basic operation of the image transfer laminator GBC Pro Tech image transfer laminators respond in a very accurate and repeatable manner The chart pro vides a way to set up each time every time for repeat able performance by assuring that all controls are set to optimum The process control chart should be ...

Page 36: ...he paper in order to maintain transfer quality until the end of the transferred image 0DFKLQH 6KXWGRZQ It is very important that the ORCA IV Image Transfer Laminator is shut down in proper manner If not the rolls can be damaged or destroyed IMPORTANT 3URFHGXUH 1 Raise the upper main roll and upper pull roll so that the rolls do not make contact with the bottom rolls 2 Turn off the main power to th...

Page 37: ...e 3M 8620 8640 etc 20 WF Overlaminate Unwind 50 WF Used Transfer Media Rewind 20WF Strip Release Liner Laminate 30 WF IMAGE TRANSFER LAMINATOR SETTINGS Top Heater Status 290 F 143 C Pull Roll Position Up or Down optional unless applying laminate Speed 1 10 fpm 3 3 0 m min max Main Roll Setting 100 psi 689 kPa Drive Direction Forward Output Cooling Idlers On Cooling Tubes Optional Drive Mode Automa...

Page 38: ...Operation ORCA IV Image Transfer Laminator Operation Manual 3 18 GBC Pro Tech 1998 October Blank page ...

Page 39: ...rolls IMPORTANT IMPORTANT IMPORTANT Daily Clean the rolls and machine Monthly Inspect the area around the image transfer laminator for possible haz ards dust buildup combustible items stored too close etc Lubricate core end plate bolts Inspect the roll lift mechanism EverySix Months Check the chain tension and lubri cate with heavy motor or gear oil Lubricate the grease fittings and chain Lubricat...

Page 40: ...l F O 554 Joy2 Lysol3 Mr Clean2 Neleco Placer PineSol4 Top Job2 Windex5 1 Registered Trademark of the Clorox Company 2 Registered Trademarks of Procter Gamble 3 Registered Trademark of Sterling Drugs 4 Registered Trademark of American Cyanamid 5 Registered Trademark of the Drackett Products Company Use the minimum amount of pressure necessary to clean the rolls You can destroy the silicone layer o...

Page 41: ...fer laminator Note Disassembly of the laminator should be performed by a qualified service technician GMXVWLQJ WKH LFN DEOH Occasionally the kick cable needs adjustment to prop erly reset after use Tools required Phillips head screwdriver To adjust the kick cable 1 Remove the kick cable cover by unscrewing the four screws and lifting the cover off 2 Check the alignment of the internal mechanism It...

Page 42: ...hnical service in North America please call 1 608 246 8844 or fax 1 608 246 8645 Please provide serial number when call ing for service In Europe please call 44 0 1844 202 440 or fax 44 0 1844 202 441 For film and application questions in North America please call 1 608 246 8844 or fax 1 608 246 8645 In Europe please call 44 0 1844 202 440 or fax 44 0 1844 202 441 ...

Page 43: ...October 4 5 Figure 4 1 Grease Fittings Grease Fitting Keep Pins 3 Well Oiled Monthly Disassemble and Grease Yearly Lubricate Slides with Grease Grease Fitting Grease Fitting Grease Fitting Pull Roll Grease Both Sides Bottom Roll Grease Main Roll Bearings Both Sides Top and Bottom Rolls Grease Fitting ...

Page 44: ...crease clutch tension Check operational settings for materials being used Problem Waves on only one side of the output Hints Check nip settings Check for even paper tension Check for proper alignment on initial setup Other Common Problems Problem Blistering in the image Hints Increase speed or lower the operating temperature Problem Coiling of encapsulated images Hints Balance the upper and lower ...

Page 45: ...t Be sure all kick cables are reset and adjusted properly Press the machine reset above main switch See Machine Reset Procedure on page 3 3 5 Display missing the decimal point e g reads 30 instead of 3 0 but the kick cables and safety buttons have been checked and the reset button has been pushed a Is the kick cable stretched out of adjustment a Verify that the kick cable is truly resetting listen...

Page 46: ...ssure on the slitter as possible to increase the life of the slitter tube 9 Rewind is not turning a Is the rewind engaged in the drive b Is there air pressure a Line up the drive tang and side shafts over to the drive side to engage them b Check for appropriate main air supply or increase the air pressure to the rewind 10 Laminate paper rewind will not turn and or you cannot set the pressure a Is ...

Page 47: ...not turn a see problem 12 a See problem 12 14 I pressed the main roll down push button but the roll did not go down a Is there air pressure to the machine b Is there at least 20 psi on the gauge c Are the e stop push buttons pressed and the kick cables reset d Is the machine reset a Verify that the air supply is suffi cient 100 psi b Turn up regulator for main roll pressure c See problem 12 d See ...

Page 48: ...on and the fan did not turn off a Is the cooling fan toggle switch set correctly a The cooling fan push button is a 4 way toggle switch keep push ing the button until the fan goes off From the off position press once to turn only the cooling idler on press twice to turn the cooling tubes only on press a third time to turn on both the cooling idler and the cooling tubes and press a fourth time to t...

Page 49: ...he machine at a slow speed Failure to do this will reduce the life of your rolls and may cause perma nent damage 30 The alarm does not come on for the conditions outlined above a Is there a technical problem with the alarm a Contact Technical Support 31 When the rolls are stopped I pressed the switch to adjust the pressure to the brakes or clutches and nothing hap pened a Are the e stop push butto...

Page 50: ...ure on page 3 3 b Reset the kick cable and reset the machine See Machine Reset Procedure on page 3 3 37 Nothing seems to work a Is the machine reset a Reset the machine See Machine Reset Procedure on page 3 3 38 Slitter is not cutting a Is the blade adjusted properly b Is the blade dull or damaged c Is the bushing that mounts the blade worn out a Check blade adjustment Setting the Slitter on page ...

Page 51: ...pply or by fire accident flood or other hazard This warranty specifically does not cover damage to the laminating rollers caused by knives razor blades other sharp objects failure caused by adhesives or improper use of the machine Warranty repair or replacement does not extend the warranty beyond the initial period from the date of delivery IMPORTANT THE WARRANTY MADE HEREIN IS IN LIEU OF ALL OTHE...

Page 52: ...Warranty ORCA IV Image Transfer Laminator Operation Manual 5 2 GBC Pro Tech 1998 October Blank page ...

Page 53: ...ters up to 15 38 1 cm Speeds 0 to 10 fpm 0 to 3 1 mpm for transfer process with variable speed and 19 fpm 5 8 mpm reversible action start and stop controlled by the instrument panel Safety Features All electrical and moving mechanical parts are located in bolted cabinets Emergency stop buttons with a reset button circuit Fully guarded with inter locks Emergency stop kick cables Options Preheater m...

Page 54: ...Specifications ORCA IV Image Transfer Laminator Operation Manual 6 2 GBC Pro Tech 1998 October Blank page ...

Page 55: ...panel 3 4 FWD REV switch 4 2 Grease fittings 4 3 Heater 2 7 Controller 2 7 Heating 3 11 Installation requirements 2 1 6 1 International shipments 2 5 Isopropyl alcohol 4 1 Jumper configurations 2 1 Kick cable 1 2 2 6 Adjusting 4 3 Laminate adhesives 3 12 Leveling 2 5 Lubrication 4 3 0 Main roll opening 6 1 Main rolls 6 1 Maintenance schedule 4 1 Material 6 1 Motor 2 7 1 Nip 1 1 1 3 3 1 2 Options 6...

Page 56: ...ne 3 16 Slitter 3 12 Specifications Dimensions 6 1 Installation requirements 6 1 Main roll opening 6 1 Main rolls 6 1 Material 6 1 Options 6 1 Speeds 6 1 Weight 6 1 Speeds 6 1 Splicing Paper 3 14 Vinyl 3 14 7 Technical support Call 1 608 246 8844 or fax 1 608 246 8645 4 4 8 Unpacking 2 4 Crate 2 4 Upper main roll 1 4 9 Vinyl transfer 3 15 Vinyl transfer and overlamination materials 3 12 Warnings a...

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