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Operation

ORCA-I SP Operation Manual

3-24

© GBC Pro-Tech 1998 April

352&(66&21752/&+$57

Product: _____________

Process: 2-Pass Cold Mount/Cold Laminate (2nd Pass)Date: ________

Material Top: ________________________

Material Bottom:3/16 Foamcore __________________

Other Material: ______________________________________________________________________

Special Instructions:___________________________________________________________________________

___________________________________________________________________________________________

___________________________________________________________________________________________

___________________________________________________________________________________________

CONTROL SETTINGS

Speed: 3-4 ft/min (1-1.2 m/min)

Reverse/Forward: Reverse

Main Roll 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)

Pull Roll Up/Down: Up

Pull Roll Pressure: 60 psi (413 kPa)

Pull Roll Shim Dials: 3/16

Cooling: Off

See Diagram 3-7A for Webbing Outline

EDNord - Istedgade 37A - 9000 Aalborg - telefon 96333500

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Summary of Contents for Pro-Tech NORD ORCA-I SP

Page 1: ...enan ce work is being perfo rmed on the mach ine All guar ds are in place All pare nt rolls are well chuc ked in the 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 jewe lry Make sure your cloth ing and hair fit close ly to your body and that all jewe lr...

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 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 par ties Thi...

Page 3: ... 3 3 3 3 Rear Control Panel 3 4 Setup 3 4 Laminator Roll Pressure 3 4 Loading the Film 3 5 Positioning the Film 3 5 Heating 3 5 Paper Tips 3 6 Laminating 51 55 Materials 3 6 Process Control Charts 3 7 Mounting Only 3 7 Setup 3 7 Procedure 3 7 Mounting Laminating 3 7 Setup 3 7 Procedure 3 7 Encapsulation 3 8 Setup 3 8 Procedure 3 8 Two Pass Mount and Laminate Hot and Cold 3 8 Setup 3 8 Procedure Pa...

Page 4: ...QJ Cleaning 4 1 Adjusting the Nip 4 3 Adjusting the Pressure Booster 4 4 Chain Tensioning 4 5 Adjusting the Air Cylinder Rate 4 6 Lubrication 4 7 Contacting Technical Support 4 7 Output Troubleshooting Guide 4 8 6HFWLRQ DUUDQW Limited Warranty 5 1 Exclusions to the Warranty 5 1 6HFWLRQ 6SHFLILFDWLRQV 6HFWLRQ QGH EDNord Istedgade 37A 9000 Aalborg telefon 96333500 ...

Page 5: ...ch to the DOWN position ensure that nothing is in the nip area In addition the laminating rolls of the ORCA I SP can reach temperatures of over 200 F 100 C At these temperatures there is a danger of a severe burn if the rolls are touched during set up operation or servicing An important feature of the laminator is the photoelec tric eye system that stops the machine when objects move into the nip ...

Page 6: ...ine stopped in such a manner that another worker can start the machine while you are working on or within the machine 6 Never change or defeat the function of electrica l interlock s or other machine shutdo wn switches 7 Before starting this machine check that All persons are clear of the machine No mainten ance work is being perform ed on the machine All guards are in place All parent rolls are w...

Page 7: ...lectrocuted or cause a fire Do not attempt to move the laminator across anything other than a flat level surface without trained and qualified riggers You can be crushed or seriously injured The ORCA I SP Laminator is a large and heavy piece of equipment It is necessary to employ LICENSED RIGGERS ONLY to move the machine The laminator is not designed to be tipped up or sideways in any way Such act...

Page 8: ... machine and possible injury to service technicians During this adjustment do not allow the main roll pressure gauge to exceed 150 psi 1030 kPa at any point Main roll pressures over 150 psi can damage the electric air valves Do not exceed 120 psi 825 kPa for the incoming air pressure Use extreme caution when operating the laminator with the footswitch The photoelectric eye system is overridden and...

Page 9: ...e the fumes Use only 80 isopropyl alcohol or a rubber cement eraser to clean the laminating rolls Harsh chemicals like toluene acetone or MEK destroy the rolls silicone covering Raise the upper main roll when the laminator is not in operation Prolonged contact can damage the rolls Excess pressure can damage the laminating rolls Always select the minimum roll pressure necessary to complete the task...

Page 10: ... items such as long hair loose clothing 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 RICHTLINIEN CONSIGNES DE SÉCURITÉ 1 Read and understand the Operation Manual and all safety labels before operating this machine 2 Only a trained person is to be ...

Page 11: ...ty over current protection and safety lock outs The laminator requires 220 to 240 VAC 50 60 Hz 55A single phase 3 wire Or in Europe only 3 N phase 230 400 VAC 50 Hz 25A per phase USA For single phase 3 wire L1 L2 and L3 are tied together with a jumper bar on the main termi nal block Europe For 3 N phase L1 L2 and L3 are each separate phases The jumper bar must be removed on the main terminal block...

Page 12: ...ibility to provide appropri ate filters and water traps for the air hose before the air is routed to the laminator GBC Pro Tech suggests that the best approach to the air requirement is to provide a dedicated small compressor for the laminator A stan dard light duty to horse power 1kW electric air compressor with 2 0 to 2 5 cfm output with a 2 5 gallon 20 liter storage tank is appropriate CAUTION ...

Page 13: ...irements 75 1 91 m 3 1m Wall 4 x 6 1 22m x 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 Supply 13 4m EDNord Istedgade 37A 9000 Aalborg telefon 96333500 ...

Page 14: ... IEN CON SIGN ES DE SÉC URIT É 1 Read and understand the Operation Manual and all safety labels before operating this machine 2 Only a trained person is to be permitted to operate this machine Training should include instruction in operation under normal conditions and emergency situations 3 This machine is to be serviced only by trained and authorized personnel Follow lockout procedures before se...

Page 15: ...dure 1 Inspect the laminator for any obvious shipping damage 2 Remove the drive and control side cabinet covers with the 1 8 hex wrench by removing the upper six screws holding each cover in place and then loos ening but not removing the lower two screws and lifting each panel off the lower screws 3 Inspect all the bolts and tighten any that were loos ened during shipping 4 Have a certified electr...

Page 16: ... to reset the machine Repeat the test for the back emergency stop kick cable WARNING Is the photoelectric eye system working With the laminator running place an object approximately the size of your hand just in front of the nip to confirm that the photoelectric eye system is functioning The rolls should stop Move the object away from the nip The laminator should resume operation WARNING Is the mo...

Page 17: ...ical and drive system components for the safety of the operator Only a quali fied service technician should open these cabinets The laminator is equipped with two emergency stop buttons located on the top of either side of the lamina tor Either of these if engaged stops the laminator and raises both the main roll and pull roll To continue operation return both emergency stop buttons to the up posi...

Page 18: ...othing 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 1033 PT Crus h and burn haza rd Stay clear of mov ing rolle rs Stop mac hine and raise roll befo re clean ing WA RN ING AC HTU NG MISE EN GAR DE 1994 HCS Inc 800 748 0241 Reorder No 1033R PT Crus h and burn haza rd Stay clear of mov in...

Page 19: ...ve the top laminating roll down 9 LOWER HEATER CONTROLLER Provides a readout of the temperature of the bottom laminat ing roll and the set point for the desired tempera ture Both heaters must be on for either heater to function 10 UPPER HEATER CONTROLLER Provides a readout of the temperature of the upper laminating roll and the set point for the desired temperature 11 AUTO STOP Starts machine for ...

Page 20: ... Use only the minimum amount of roll pressure needed to accomplish the task While higher pressure can make the adhesive bond faster excess pressure can damage the rolls Wrinkles and bubbles have causes that gener ally cannot be cured by applying more pressure CAUTION A typical roll pressure for soft substrates such as Foam core is between 20 to 30 pounds per square inch psi or 140 to 205 kPa The r...

Page 21: ...Return the arm to its locked position and reinsert the locking pin 4 Center the film on the unwind arm by measuring the distance from the ends of the film to the sides of the machine using a tape measure HDWLQJ Use the following instructions when heating one or both of the laminating rolls The procedure is the same for the top and bottom heaters 1 Set the heater switch to ON Both controllers must ...

Page 22: ... the roll Note The paper unwind might require two evenly spaced core supports 2 Place the roll on the unwind shaft 3 Carefully close the unwind shaft holding the roll away from the hinge to prevent pinching the end of wide rolls 4 When the shaft is in the saddle push in the locking pin 5 Center the roll of material Note Position 55 rolls slightly off center as needed to clear the brake support bra...

Page 23: ...ING 0RXQWLQJ 2QO 6HWXS 1 See process charts 3 1 and diagram 3 1a 2 Set the controls as follows Shims Set to the thickness of the material being used for mounting Main Roll Air Pressure 40 psi 275 kPa Speed Adjust 3 fpm 1 m min Upper Heater Controller 220 F 104 C 3URFHGXUH 1 Lay the print on the board Using a tack iron tack the leading edge of the print down onto the board so it is held in place 2 ...

Page 24: ...nts Be sure that the mounting film from the bottom side has the sticky adhesive side riding up around the out side of the bottom laminating roll 3URFHGXUH 3DVV 1 Run the print through to apply adhesive and lami nate 2 Trim to slightly larger than the desired finished size 3URFHGXUH 3DVV 1 Prepare to put the print through a second time to mount the print to the substrate such as wood Mas inote Gato...

Page 25: ...HGXUH 3DVV 1 See process chart 3 8 and diagram 3 8a for mate rial mounting instructions and machine adjust ments 2 Web the vinyl up around the bottom main roll and over to the pull roll Make sure the material is webbed straight and lower the pull roll to hold the vinyl 3 Web the paper through as shown in diagram 3 8a Often when paper is not on a core hand tension must be applied to the paper in or...

Page 26: ..._________________________________________________________ ___________________________________________________________________________________________ ___________________________________________________________________________________________ ___________________________________________________________________________________________ CONTROL SETTINGS Speed Reverse Forward Main Roll Up Down Main Roll...

Page 27: ...agram Upper Pull Roll Lower Pull Roll Upper Main Roll Lower Main Roll Rewind Upper Film Unwind Brake Tension Lower Film Unwind Paper Unwind Stationary Idler Main Roll Shim Setting Pull Roll Shim Setting Rewind Stationary Idler Output Slitters optional EDNord Istedgade 37A 9000 Aalborg telefon 96333500 ...

Page 28: ..._______________________________________________ ___________________________________________________________________________________________ ___________________________________________________________________________________________ CONTROL SETTINGS Speed 3 ft min 1 m min Reverse Forward Forward Main Roll Up Down Down Main Roll Pressure 40 psi 275 kPa Top Heater On Off On Top Temp Set 220 F 104 C B...

Page 29: ... 13 352 66 21752 5 0 Adjust Shim Setting For Board Thickness Hot Upper Main Roll Lower Main Roll Upper Pull Roll Lower Pull Roll Contact Release Paper Print Tape Front Edge of Print to Board Adhesive Coated Board EDNord Istedgade 37A 9000 Aalborg telefon 96333500 ...

Page 30: ...________________________________________________________ ___________________________________________________________________________________________ ___________________________________________________________________________________________ CONTROL SETTINGS Speed 3 ft min 1 m min Reverse Forward Forward Main Roll Up Down Down Main Roll Pressure 40 psi 275 kPa Top Heater On Off On Top Temp Set 220 ...

Page 31: ... 3 15 352 66 21752 5 0 Adjust Shim Setting For Board Thickness Hot Upper Main Roll Upper Film Unwind Print Adhesive Coated Board Tape Front Edge of Print to Board Lower Main Roll Upper Pull Roll Lower Pull Roll EDNord Istedgade 37A 9000 Aalborg telefon 96333500 ...

Page 32: ...___________________ ___________________________________________________________________________________________ ___________________________________________________________________________________________ CONTROL SETTINGS Speed 3 8 ft min 0 9 2 5 m min Reverse Forward Forward Main Roll Up Down Down Main Roll Pressure 60 80 psi 413 550 kPa Top Heater On Off On Top Temp Set 220 F 104 C Bottom Heater ...

Page 33: ... Roll Hot Upper Main Roll Hot Lower Main Roll Roll Feed option Rewind of Finished Product Upper Film Unwind Sheet Feed option Roll of Printed Images Lower Film Unwind Trimmed Excess Paper Optional Paper Cutter for use with rolled paper Output Slitters optional EDNord Istedgade 37A 9000 Aalborg telefon 96333500 ...

Page 34: ..._____________________________________ ___________________________________________________________________________________________ ___________________________________________________________________________________________ CONTROL SETTINGS Speed 4 6 ft min 1 2 2 m min Reverse Forward Forward Main Roll Up Down Down Main Roll Pressure 60 80 psi 413 550 kPa Top Heater On Off On Top Temp Set 220 F 104 ...

Page 35: ...9 352 66 21752 5 0 Upper Pull Roll Lower Pull Roll Hot Upper Main Roll Rewind of Finished Product Laminate Cold Lower Main Roll Roll Feed option Sheet Feed Mount Adhesive with Release Liner Output Slitters optional EDNord Istedgade 37A 9000 Aalborg telefon 96333500 ...

Page 36: ...__________________________________________________________________ ___________________________________________________________________________________________ ___________________________________________________________________________________________ CONTROL SETTINGS Speed 3 4 ft min 1 1 2 m min Reverse Forward Reverse Main Roll Up Down Up Main Roll Pressure Top Heater On Off On or Off Top Temp Se...

Page 37: ... 21752 5 0 Adjust Shim Setting For Board Thickness 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 EDNord Istedgade 37A 9000 Aalborg telefon 96333500 ...

Page 38: ..._______________________________________________________________ ___________________________________________________________________________________________ ___________________________________________________________________________________________ CONTROL SETTINGS Speed 4 6 ft min 1 2 2 m min Reverse Forward Forward Main Roll Up Down Down Main Roll Pressure 80 psi 550 kPa Top Heater On Off Off Top...

Page 39: ...r Pull Roll Lower Pull Roll Warm Upper Main Roll Rewind of Finished Product Warm Lower Main Roll Roll Feed option Sheet Feed Mount Adhesive with Release Liner Release Liner Rewind Cold Laminate with Release Liner Output Slitters optional EDNord Istedgade 37A 9000 Aalborg telefon 96333500 ...

Page 40: ..._____________________________________________ ___________________________________________________________________________________________ ___________________________________________________________________________________________ CONTROL SETTINGS Speed 3 4 ft min 1 1 2 m min Reverse Forward Reverse Main Roll Up Down Up Main Roll Pressure Top Heater On Off Off Top Temp Set Bottom Heater On Off Off ...

Page 41: ... 21752 5 0 Adjust Shim Setting For Board Thickness 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 EDNord Istedgade 37A 9000 Aalborg telefon 96333500 ...

Page 42: ...________________________________ ___________________________________________________________________________________________ ___________________________________________________________________________________________ CONTROL SETTINGS Speed 1 3 fpm 0 3 0 9 m min Reverse Forward Forward Main Roll Up Down Down Main Roll Pressure 90 120 psi 619 825 kPa Top Heater On Off On Top Temp Set 290 F 143 C Bot...

Page 43: ...ration GBC Pro Tech 1998 April 3 27 352 66 21752 5 0 Transfer Media Transfer Media Rewind Infeed Trim Tape Front Edge of Print to Board Vinyl Product Rewind Output Slitters optional EDNord Istedgade 37A 9000 Aalborg telefon 96333500 ...

Page 44: ..._______________ ___________________________________________________________________________________________ ___________________________________________________________________________________________ CONTROL SETTINGS Speed 1 8 ft min 0 3 2 5 m min Reverse Forward Forward Main Roll Up Down Down Main Roll Pressure 70 90 psi 481 825 kPa Top Heater On Off Off Top Temp Set 32 F 0 C Bottom Heater On Off...

Page 45: ...ion Manual Operation GBC Pro Tech 1998 April 3 29 352 66 21752 5 0 Release Liner Rewind Vinyl With Image Finished Product Rewind Overlaminate Output Slitters optional EDNord Istedgade 37A 9000 Aalborg telefon 96333500 ...

Page 46: ...Operation ORCA I SP Operation Manual 3 30 GBC Pro Tech 1998 April Blank page EDNord Istedgade 37A 9000 Aalborg telefon 96333500 ...

Page 47: ... roll temperature Inspect the electrical cord for dam age Inspect the footswitch cord for dam age Monthly Adjust the nip Align adjust the IR sensors if neces sary Check the chain tension Inspect the area around the laminator for possible hazards dust buildup combustible items stored too close etc Adjust the air cylinder rates EverySix Months Lubricate the grease fittings and chain Check wire termi...

Page 48: ...ted adhesive off the rolls when they are cold You can cause irreparable damage to the laminating rolls Use the minimum amount of pressure necessary to clean the rolls You can destroy the silicone layer on the rolls by pressing too hard or scrubbing too long in one spot Exercise care when cleaning the rolls with 80 isopropyl alcohol Use only in a well ventilated area Wear rubber gloves Use only on ...

Page 49: ...n the lock collar up several turns to allow the upper main roll to rest on the lower main roll when lowered 5 Set the shim dial to zero 0 6 Repeat steps 3 5 for the laminator s drive side 7 Set the main roll pressure to 30 40 psi 205 275 kPa 8 Turn the UP DOWN switch on the front control panel to the DOWN position to lower the upper main roll Allow it to settle for approximately 10 seconds CAUTION...

Page 50: ...down when each collar is tight 10 Tighten the set screw in each lock collar 11 Replace both cabinet covers GMXVWLQJ WKH 3UHVVXUH RRVWHU WARNING 1 Before installing an incoming air supply that is greater than 100 psi 700 kPa and less than 120 psi 825 kPa close the pressure booster by gently pulling out on the pressure booster regulator knob and rotating it counterclockwise as far as possible See th...

Page 51: ...tension WARNING 1 Remove the drive side cabinet cover by removing the screws with the 1 8 hex wrench 2 Move the automatic chain tensioner off the chain 3 Loosen but do not remove all four motor mount bolts using the 3 16 hex wrench as shown in the figure below The motor should just move freely within the slots Figure 4 4 Adjusting the Chain Tension 4 Using a screwdriver apply a small amount of dow...

Page 52: ...net covers if no further adjust ments are needed To adjust the air cylinder rate for the pull rolls The adjustment procedure for the pull rolls is similar to the adjustment procedure for the main rolls 1 Make sure there is both air and power to the machine 2 If necessary remove both cabinet covers 3 Loosen the large knurled locking rings 4 Turn the pull roll air cylinder adjustment valve knobs on ...

Page 53: ...e call 44 0 1844 202 440 or fax 44 0 1844 202 441 For film and application questions in North America please call 1 800 236 8843 In Europe please call 44 0 1844 202 440 or fax 44 0 1844 202 441 Do not lubricate the laminator when it is hot You can be burned Remove power from the laminator and make sure it cannot be reapplied while you are performing this procedure You could be severely shocked ele...

Page 54: ...of the output Hints Check nip settings Check for even paper tension Other Common Problems Problem Blistering in the image Hints Increase speed or lower the operating temperature Problem Coiling of encapsulated images Hints Balance the upper and lower unwind brake tension Make sure main roll temperatures are the same Adjust cooling fans Problem Longitudinal waves or stuttering jerking or excessive ...

Page 55: ...rom the date of delivery CAUTION THE WARRANTY MADE HEREIN IS IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING ANY WARRANTY OR MERCHANTABILITY OR FITNESS FOR A PAR TICULAR PURPOSE GBC PRO TECH WILL NOT BE LIABLE FOR PROPERTY DAMAGE OR PER SONAL INJURY UNLESS PRIMARILY CAUSED BY ITS NEGLIGENCE LOSS OF PROFIT OR OTHER INCIDENTAL OR CONSEQUENTIAL DAMAGES ARISING OUT OF THE USE OR INABILITY...

Page 56: ...Warranty ORCA I SP Operation Manual 5 2 GBC Pro Tech 1998 April Blank page EDNord Istedgade 37A 9000 Aalborg telefon 96333500 ...

Page 57: ... speed reversible action start and stop controlled either through the instrument panel or with the footswitch Encapsulating Features Pull rolls and cooling fans for uniform flat cooling Safety Features Photoelectric eyes prevent laminating roll movement if objects are in the nip area All electrical and moving mechanical parts are located in bolted cabinets 2 emergency stop buttons 2 emergency kick...

Page 58: ...Specifications ORCA I SP Operation Manual 6 2 GBC Pro Tech 1998 April Blank page EDNord Istedgade 37A 9000 Aalborg telefon 96333500 ...

Page 59: ...peeds 6 1 Lubrication 4 7 0 Main rolls 4 3 Maintenance schedule 4 1 Motor 2 6 1 Nip 1 1 2 5 2 6 3 1 4 1 4 3 6 1 Main roll adjusting 4 3 2 Outfeed slitters 6 1 Outfeed table 6 1 3 Photoelectric eye 1 1 2 6 3 1 Power cord 2 1 Preinstallation checklist 2 1 Pressure Booster 4 4 Pull rolls 4 4 5 Riggers 1 3 2 4 2 5 Roll to roll transfer 3 9 Rubber cement eraser 4 1 6 Safety features 6 1 Safety informat...

Page 60: ...Index ORCA I SP Operation Manual 7 2 GBC Pro Tech 1998 April 9 Vacuum table 6 1 Warnings and cautions 1 1 Warranty 5 1 EDNord Istedgade 37A 9000 Aalborg telefon 96333500 ...

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