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ORCA-I Operation Manual

Operation

 GBC Pro-Tech 1997 October

3-7

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Process control charts allow you to record the way
you thread film through the machine's rolls and idlers
(called webbing) and the control settings for each
product and process. Process control charts are an
excellent tool for training new operators. They
provide a "road map" for correct machine setup and
operation.

This section contains a blank process control chart
and diagram for the ORCA-I as well as completed
charts for the basic operations of the laminator.

GBC Pro-Tech laminators respond in a very accurate
and repeatable manner. The charts provide a way to
set up each time, every time for repeatable
performance by assuring that all controls are set to
optimum.

The process control charts should be kept in this
manual or in a book close to the laminator. Use the
machine to encapsulate the popular charts so they can
withstand food and coffee spills and so they are
always available for ready reference.

⇒

 

NOTE

When trying new products and processes, remember
that GBC Pro-Tech's customer service
representatives are only a phone call away. In North
America, please call 1-800-236-8843.

The completed process control charts included in this
section are based on Orca-Film and typical prints.

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6HWXS

1.

 

See process charts 3-1 and diagram 3-1a.

2.

 

Shims: Set to the thickness of the material being
used for mounting.

3.

 

Upper Laminator Roll Pressure: 40 PSI (275
kPa).

4.

 

Speed: 3 fpm (1 m/min).

5.

 

Upper Laminator Roll Heat: 240°F (115 °C).

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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.

 

Put a piece of contact/release paper over the print
and board. Otherwise, adhesive will be applied to
the laminating roll, which can cause damage and
the ink from electrostatic prints will be deposited
on the roll.

3.

 

Feed the print/board package through the nip.

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The following procedure is for one-step mounting and
heat-activated laminating using mounting board with
one adhesive side.

6HWXS

1.

 

See process chart 3-2 and diagram 3-2a.

2.

 

Mount the film and web as shown in diagram
3-2a.

3.

 

Shims: Set the two front shim dials to the
substrate thickness.

4.

 

Laminator Roll Pressure: 40 PSI (275 kPa).

5.

 

Speed: 3 fpm (1 m/min).

6.

 

Upper Laminator Roll Heat: 240°F (115 °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.

 

Feed the print/board package through the nip.

EDNord - Istedgade 37A - 9000 Aalborg - telefon 96333500

Содержание ORCA-I

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

Страница 2: ...ts described in it without notice All specifications and information concerning products are subject to change without notice Reference in this publication to information or products protected by copy...

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

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

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

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

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

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

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

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

Страница 11: ...e injured by inhaling chemical vapors Vapor build up or stored flammable liquids can cause a fire Excessive dust can damage the laminator CAUTION Do not locate the laminator where air is blowing direc...

Страница 12: ...laminator to malfunction It is the customer s responsibility to provide appropriate filters and water traps for the air hose before the air is routed to the laminator GBC Pro Tech suggests that the b...

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

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

Страница 15: ...word about international shipments As these are heavy pieces of equipment GBC Pro Tech takes every precaution to ensure that our laminators are properly crated to the highest standards Before machine...

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

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

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

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

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

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

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

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

Страница 24: ...unting film from the bottom side has the sticky adhesive side riding up around the outside of the bottom laminating roll 3URFHGXUH 3DVV 1 Run the print through to apply adhesive and laminate 2 Trim to...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 49: ...f the output Hints Check nip settings Check for even paper tension Other Common Problems Problem Blistering in the image Hints Increase speed or lower the operating temperature Problem Coiling of enca...

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

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

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

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

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

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

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

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