GBC 80-99 User Manual

ORCA 80-99 OPERATION

& MAINTENANCE MANUAL

Do not duplicate without written permission.

GBC Pro - Tech

4151 Anderson Road

DeForest, WI 53532

Revision : Ph: ( 608 ) 246 - 8844

Part number : 930 - 055

Fx: ( 608 ) 246 - 8645

Section 1: Safety

Safety features .............................................................................. 1 - 1

Section 2: Warranty

Limited warranty information ..................................................... 2 - 1

Exclusions to the warranty .......................................................... 2 - 1

Table of ContentsOrca 80-99 Operation and Maintenance Manual

Table of Contents

Section 3: Specifications

Section 4: Installation

Uncrating ........................................................................................ 4 - 1

Uncrating Diagram........................................................................4 - 2

Electrical Requirements ................................................................4 - 3

Suggested Layout ...........................................................................4 - 4

Air Requirements...........................................................................4 - 5

Page I

Table of Contents Orca 80-99 Operation and Maintenance Manual

Section 5: Operations

Operation....................................................................................... 5 - 1

Front control panel diagram ........................................................ 5 - 2

Rear control panel diagram ......................................................... 5 - 3

Front control panel....................................................................... 5 - 4

Rear control panel........................................................................ 5 - 4

Setup .............................................................................................. 5 - 5

Processes....................................................................................... 5 - 7

Process control chart (blank) ...................................................... 5 - 10

Process control diagram (blank)................................................. 5 - 11

Hot mount (Chart 2.2) .................................................................. 5 - 12

Hot mount (Diagram 2.2) ............................................................. 5 - 13

Hot mount/Laminate (Chart 2.3)................................................. 5 - 14

Page II

Hot mount/Laminate (Diagram 2.3)............................................ 5 - 15

Table of ContentsOrca 80-99 Operation and Maintenance Manual

Encapsulation (Chart 2.4)............................................................ 5 - 16

Encapsulation (Diagram 2.4) ........................................................5 - 17

Hot laminate/PSA mount (Chart 2.5)...........................................5 - 18

Hot laminate/PSA mount (Diagram 2.5)......................................5 - 19

Hot laminate/PSA mount (Second pass - Chart 2.6) ..................5 - 20

Hot laminate/PSA mount (Second pass - Diagram 2.6) ............5 - 21

Cold overlaminate/ PSA mount (Chart 2.7) ................................5 - 22

Cold overlaminate/PSA mount (Diagram 2.7) ............................5 - 23

Cold overlaminate/PSA mount (Second pass - Chart 2.8).........5 - 24

Cold overlaminate/PSA mount (Second pass - Diagram 2.8)....5 - 25

Cold laminate only using a sled (Chart 2.9) ................................5 - 26

Cold laminate only using a sled (Diagram 2.9)...........................5 - 27

Page III

Table of Contents Orca 80-99 Operation and Maintenance Manual

Section 6: Maintenence

Daily ................................................................................................ 6 - 1

Monthly...........................................................................................6 - 1

Six Month .......................................................................................6 - 2

Chain Diagram ...............................................................................6 - 3

Page IV

SAFETY

SafetyOrca 80-99 Operation and Maintenance Manual

READ THIS SECTION BEFORE

OPERATING THE ORCA 80-99 LAMINATOR!

FOR YOUR SAFETY:

Your safety as well as the safety of others is important to GBC Pro-Tech. In this instruction and on the product are important safety messages. Read these messages carefully.

1. Read all these instructions.

2. Save these instructions for later use.

3. Follow all warning and instructions marked on the

product.

4. Unplug this product from the wall outlet before cleaning. Do not use liquid cleaners or aerosol cleaners. Use a damp cloth for cleaning.

5. Do not use this product near water.

6. This product should be operated from the type of

power source indicated on the marking label. If you are not sure of the type of power available, consult your dealer or a qualified and certified electrician.

10. Unplug this product from the wall outlet and refer servicing to qualified service personnel under the following conditions:

A. When the power cord is damaged or frayed.

B. If liquid has spilled into the product.

C. If the product has been exposed to rain or water.

WARNING:

Never place fingers or arms between the rollers when they are turning or when the rollers are in the closed position.

D. If the product does not operate normally when the

operating instructions are followed. Adjust only those controls that are covered by the operating instructions since improper adjustment of other controls may result in damage and will often require extensive work by a qualified technician to restore the product to normal operation.

E. If the product exhibits a distinct change in performance, indicating a need for service.

Safety Information

7. Do not allow anything to rest on the power cord. Do

not locate this product where persons will walk on the cord.

8. Never push objects of any kind into this product through any slots as they may touch dangerous voltage points or short out parts that could result in a risk of fire or electric shock. Never spill liquid of any kind on the product.

9. Do not attempt to service this product yourself, as opening or removing covers may expose you to dangerous voltage points or other risks. Refer all servicing to service personnel.

WARNING:

It is vital that everyone working around the laminator rolls avoid wearing loose-fitting clothing, ties or dangling jewelry which could be caught in the nip.

The GBC Pro-Tech laminator has been designed with operator safety as a primary consideration. However, operators must become thoroughly familiar with the controls, and proper operation and safety features of the machine before starting to use the unit.

Page 1 - 1

Safety Orca 80-99 Operation and Maintenance Manual

GBC Pro-Tech laminators are powerful machines which are designed to accomplish specific tasks such as mounting, laminating and encapsulating. The forces required to accomplish laminating can vary from negligible to very large. The air-cylinder system used to provide downward pressure on the top roll is capable of producing forces greater than 1000 pounds (454 kg). This force can be applied to any object that may be present in the opening (called the nip) between the two rollers.

As a safety measure, the laminator is equipped with a photoelectric eye system which stops the machine when objects or hands are located in the nip area. Once the blocking object is removed and the light beam is reestablished, the laminator rolls resume turning.

Operators should use care in lowering the top laminating roll and know how to react quickly in an emergency. The laminator roll UP-DOWN switch is located on the front instrument panel labeled “Laminator Roll Controls” on the left-hand side of the machine. As the name implies, this switch controls the up and down motion of the top laminator roll. Before turning this switch to the DOWN position, assure that nothing is in the nip area.

machine, or by stepping on or kicking the E-Stop cable located at the bottom of the machine.

Quick action in this regard can aid in preventing or minimizing injury or machine damage.

Because of the electrical shock hazard and the chance that a person might get either fingers or clothing into the drive mechanism, the cabinets should only be opened by a qualified service person, after the machine is shut off and the power disconnected.

Most GBC Pro-Tech machines are designed to heat the lamination rollers. Temperatures can be set to over 200 degrees F (100 degrees C). Thus there is a danger of a severe burn if the rollers are touched during set-up or operation. The machines have steel end cabinets that are bolted closed. They serve to isolate the electrical- and drivesystem components.

WARNING:

Please note: All persons working on or near the Orca 80-99 Laminator must be advised of the following:

If any clothing, tools, or anything other than film or paper is inadvertently drawn into the nip, the action of the rolls may be halted immediately (and the top roll lifted) by pushing or striking any of the red E-Stop switches located at the top of the

Page 1 - 2

Orca 80-99 Operation and Maintenance Manual

WARRANTY

Limited Warranty

Warranty

CAUTION:

Unauthorized customer alterations will void this warranty.

GBC Pro-Tech warrants the equipment sold is free from defects in material and workmanship for a period of one

(1) year from the date of delivery to the customer.

This warranty is the only warranty made by Pro-Tech and can not be modified or amended.

GBC Pro-Tech’s sole and exclusive liability and the customer’s sole and exclusive remedy under this warranty shall be, at GBC Pro-Tech’s option, to repair or replace any such defective part or product. These remedies are only available if GBC Pro-Tech’s examination of the product discloses to GBC ProTech’s satisfaction that such defects actually exist and were not caused by misuse, neglect, attempt to repair, unauthorized alteration or modification, incorrect line voltage, contaminated air supply, or by fire, accident or flood or other hazard.

Exclusions to the Warranty

This warranty specifically does not cover:

1. Damage to the laminating rollers caused by knives, razor blades, other sharp objects, or failure caused by adhesives.

2. Damage to the machine caused by lifting, tilting, and/or any attempt to position the machine other than rolling on the installed casters.

3. Improper use of the machine.

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 one year period from the date of delivery.

THE WARRANTY MADE HEREIN IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING ANY WARRANTY OR MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. GBC PRO-TECH WILL NOT BE LIABLE FOR PROPERTY DAMAGE OR PERSONAL INJURY (UNLESS PRIMARILY CAUSED BY ITS NEGLIGENCE), LOSS OF PROFIT OR OTHER INCIDENTAL OR CONSEQUENTIAL DAMAGES ARISING OUT OF THE USE OR INABILITY TO USE THE EQUIPMENT.

Page 2 - 1

ORCA 80-99

SPECIFICATIONS

SpecificationsOrca 80-99 Operation and Maintenance Manual

Description:

Floor-standing laminator with multiple unwind positions for high productivity heat-activated laminating, encapsulating, heat transfer and mounting. The laminator can also be used with pressure-sensitive films for cold mounting and laminating applications.

Includes:

Outfeed edge slitters for in line trimming of finished product.

Dimensions:

L - 120", D - 50", H - 66" (L- 3M, D- 1.27M, H-

1.68M)

Weight (uncrated):

Laminating Material:

Uses heat-activated 0-74” and pressure-sensitive materials 0 - 80" (0- cm) wide with films on 3" (7.6 cm.) ID core.

Laminating Speeds:

0 to 30 fpm ( 0 to 9 Mpm) with variable speed, reversible action, START and STOP controlled via the front instrument-panel switch or with a foot switch.

Unwind - Rewind:

Three unwind positions; three rewind positions

Safety Features:

(1) Photo-eye motor stop, 4 emergency stop buttons and two kick cables to stop the machine and raise rolls.

2800 pounds (1270 kg)

Laminating Rolls:

86.5" length (220 cm) roll face with thermally conductive silicone covered with high release silicone surface, upper and lower rolls internally heated. Temperature controlled by state of the art infrared sensors with closed loop digital control systems, independently adjustable for both top and bottom rolls.

Laminating Opening:

1_” (4.75 cm) maximum opening controlled with dual air cylinders.

Warranty:

One year parts warranty (except silicone roll coverings and table tops).

Electric:

220 VAC, 50 or 60 Hz, single phase, 60-65 Amps. Three phase 32 Amps (Europe only).

Compressed Air:

2 CFM @ 100 PSI.

Page 3 - 1

INSTALLATION

Uncrating the Machine

InstallationOrca 80-99 Operation and Maintenance Manual

CAUTION:

When taking the top off, care should be taken so that the top does not fall into the crate, possibly damaging the laminator. It might be necessary to use two or three people for this task.

During the uncrating process make sure that the screws do not end up on the floor. They can cause problems later when trying to roll the machine into position.

To uncrate the Orca 80-99 Laminator you will need a phillips head screwdriver. It helps to have a cordless drill with the screwdriver bit, because there are quite a few screws to remove throughout this procedure. In order to minimize the possibility of damage to your new Orca 8099 Laminator, please follow this procedure exactly.

1. The top of the crate is the first piece to be removed (see diagram on page 4-3).

2. Next, remove one side of the crate (see diagram). At this point it is necessary to have someone support the remaining side of the crate while the remaining end is being removed. Maintain support of the side until all mounting screws are removed and the side is off the crate.

6. When all the accessories have been removed from the crate you will notice that there are two ramps that are bolted down to the crate bottom: these will need to be removed, using the phillips head screwdriver.

The ramps must then be secured to the edge of the crate bottom using the screws left over from crate disassembly (see diagram).

PLEASE NOTE: The Orca 80-99 Laminator is a large and heavy piece of mechanical equipment. Casual movement of equipment of this type can be hazardous to the average person; and poses the potential of serious damage to the machine.

It will be necessary to employ qualified and trained personnel (licensed, certified RIGGERS) if any movement of the machine other than rolling on a flat, level surface is contemplated.

The Orca 80-99 Laminator is not designed to be tipped up or sideways in anyway. Such action may disturb the exact alignment of the rolling parts of the machine and require extensive re-alignment. GBC Pro-Tech’s warranty does not cover malfunction of the equipment due to mis-handling and/or tipping.

3. Remove the end of the crate (see diagram).

CAUTION:

Do not use a knife or other sharp instrument to remove any protective covering. This could cause irreparable damage to the machine.

4. Remove the shrink wrap from the machine and its

contents.

5. Once the shrink wrap is off, remove any accessories from the crate. While doing this, take care not to scuff the machine.

GBC Pro-Tech bears no responsibility for parties who fail to follow these directions. Any injury or damage to the machine due to improper moving is the sole responsibility of the mover.

Before the machine can be rolled off the crate, the foot bolts must be freed from the four shipping hold-down plates. Loosen the lock-nut on each of the foot bolts.

Unscrew the foot bolts from the hold-down plates. Raise but do not remove the bolts and lock nuts from the foot bracket. (At this time, you may wish to remove the holddown plates from the crate to provide unrestricted removal of the machine from the crate).

Page 4 - 1

Page 4 - 2

Installation

UNCRATING DIAGRAM

ORCA-80-99

INSTALL SCREWS

Orca 80-99 Operation and Maintenance Manual

23 in.

[59 cm]

InstallationOrca 80-99 Operation and Maintenance Manual

7. Once the ramps are secured and the hold down plates

are removed, the machine can be rolled off the crate bottom. This will require four people handling the machine on its four corners and carefully rolling the machine off the crate bottom (see diagram). The machine can now be rolled into its final operating position.

Choose a spot with sufficient space around the unit so that there can be front and back work tables and adequate space for efficient material flow. Thus, a typical room area requirement for the ORCA 80-99 is 20 X 24 feet (6.0 x

7.3 Meters) to allow use of work tables in front and to the rear of the machine. See the suggested layout in Fig. 1-1 (page 4-4).

Once the Orca 80-99 Laminator has been placed in its final position, optimum performance is obtained by installing the supplied leveling pads and leveling the machine. Install one leveling pad on each foot-bolt, tightening securely.

Lower the leveling pad to the floor by turning down the foot bolts. Turn all the bolts sufficiently to lift all four of the casters off the floor.

CAUTION:

Some generation of static electricity is unavoidable during the laminating process due to the nature of the materials used. In order to avoid any hazard of ignition, fire or explosion due to static spark, it is imperative that the operating environment is free of dust, flammable liquids, and vapors.

Then, face the machine and place a carpenter’s level leftto-right on one of the idlers. Adjust the bolts on the front two foot brackets so that the machine is level left-to-right. Then, move the level to the rear of the machine and adjust the rear two leveling pads.

Next, place the level front-to-rear on one of the air cylinder brackets and adjust the bolts equally on the two foot brackets on that side. Move the level to the other air cylinder bracket and repeat the procedure for the other side.

After both sides have been leveled front-to-back, go back and check the side-to-side level condition of the front

and rear of the machine to insure that it has not changed.

If it has, repeat the procedure until the machine’s front, rear, and both sides are all level. Tighten the lock nuts securely to the foot brackets.

8. At this point a qualified electrician connects power to the machine. Make sure before supply power is provided that the machine circuit breaker is in the off position. This is also the point where the appropriate supply of clean, dry compressed air is connected to the machine (see power and air requirements).

Electrical Requirements

The ORCA 80-99 is designed to accept 220 to 240-volt AC, 50/60-Hz, 60 Amps, single phase 3 wire (USA). The peak power required by the unit is 55 Amperes. Or, in Europe only 3-N phase 230/400 VAC, 50 Hz, 25 Amps per phase.

Before attempting to electrically connect or operate your new Orca 80-99 Laminator, a qualified, licensed electrician should be consulted to ensure that an adequate power supply, having the appropriate capacity, overcurrent protection, safety lockouts, etc., is available; and to ensure that the power supply of the Orca 80-99 is in accordance with all established national and regional electrical codes and standards.

CAUTION:

The air supply to the Orca must be clean and dry or the machine will be damaged.

GBC Pro-Tech, will not be responsible for damage to the equipment caused by improper connection, incorrect power supply or other incorrect electrical installation.

Before initial power is applied to the machine assure that all toggle switches on the front and rear control panels and the main power circuit breaker (inside/bottom of the

left-side cabinet) are set to OFF. The AC connection is located on the bottom/front of the left-side cabinet.

Page 4 - 3

Installation

AIR SUPPLY

Orca 80-99 Operation and Maintenance Manual

Work Table

6' X 6'

[2m x 2m]

(on wheels)

REAR

10' [3m]

ELECTRICAL

SUPPLY

20' [6m]

FRONT

10' [3m]

Work Table

6' X 6'

[2m x 2m]

(on wheels)

4' [1.2m]

[1m

]

24' [7.3m]

Page 4 - 4

Fig. 1-1

SUGGESTED WORKSPACE

LAYOUT

ORCA 80-99

Air Requirements

CAUTION:

Do not use a knife or other sharp object to remove the paper coverings. This would cause irreparable damage to the rolls and necessitate their replacement.

The Orca 80-99 laminator requires filtered air at 2 cubic feet per minute (CFM), (50 liters/minute) at a pressure of at least 100 pounds (700 kPa) per square inch (PSI). The air supply must be clean (free of dirt) and dry. Moisture will cause corrosion and particles can block pneumatic controls. Either can cause the laminator to malfunction.

InstallationOrca 80-99 Operation and Maintenance Manual

2 Additional slitter knives 1 T-handle wrench, 5/16" 1 T-handle wrench, 1/4" 1 Masking Tape 1 Tape Measure 1 Rubber Cement Pick-Up 1 Shim Set 4 Leveling Pads 2 Outfeed Slitters 2 O-Rings, Brake 1 Oil, Air Tool

These items are needed to put the machine into operation.

RECYCLING INSTRUCTIONS:

It is the customer’s responsibility to provide appropriate filters and water traps for the air line 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 standard light-duty 1/2 to 3/4 horsepower (1 kW) electric air compressor with 1.5 to

2.5 CFM output with a 2.5 - gallon (20 Liter) storage tank is appropriate.

Air is fed to the machine via a 1/4-inch quick-disconnect male connector. This connector is located below the cabinet on the left side of the machine. (Once the air supply and electrical power are connected to the machine, proceed to the section on Operation in this manual).

9. Next, remove the paper coverings from the roll. After the roll coverings have been removed, you will need to open the accessory pack. The accessory pack contains:

The crate components can be reused for shipping the machine again, or may be disassembled and the wood and screws recycled. The shrink wrap however, is not recyclable so therefore must be discarded.

In order to begin operation of the machine, the Up/Down rates for the main and pull rolls and the nips must be set (see the Operation section of this manual). Once set, the machine is ready for operation.

Qty Description

1 Set, Allen wrenches 1 Slitting knife 1 Manual 1 Bottle of Isopropyl Alcohol 1 100 % white cotton terry rags 1 Set, spare fuses

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