GBC OORCA-III Operation Manual

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© 1997 GBC Pro-Tech

Do not duplicate without written permission

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LAMINATOR ROLL CONTROLS

POWER

FAN TABLE

PRO-TECH Engineering Madison,WI 608-246-8844

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SPEED

MOTOR CONTROLS

BOTTOM

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DANGER
GEFAHR

HAZARDOUS
VOLTAGE.

o. 5025-PT

To be serviced only

eorder N
R

by trained and
authorized personnel.
Lockout power before
servicing.

s, Inc. 800-748-0241

unication System

m
om
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azard
1994 H
©

4151 Anderson Road

De Forest, Wisconsin 53532

Part Number 930-402 Rev. A

GBC Pro-Tech

Tel: [phone]

Fax: [phone]

ORCA-III Operation Manual

The information in this publication is provided for reference and is believed to be
accurate and complete. GBC Pro-Tech is not liable for errors in this publication or for
incidental or consequential damage in connection with the furnishing or use of the
information in this publication, including, but not limited to, any implied warranty of
fitness or merchantability for any particular use.

GBC Pro-Tech reserves the right to make changes 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 any other rights
of third parties.

This Manual is Copyrighted © 1997 by GBC Pro-Tech. All rights reserved. The
information contained in this manual 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 Pro-Tech .

ii



GBC Pro-Tech 1997 October

ORCA-III Operation Manual

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Caution/Warning Label Locations.......................................................................................1-5

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Preinstallation Checklist......................................................................................................2-1

Unpacking............................................................................................................................2-4

Setup...................................................................................................................................2-5

Leveling...............................................................................................................................2-6

Startup.................................................................................................................................2-6

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Safety ..................................................................................................................................3-1

Operator Controls................................................................................................................3-3

Operator Controls................................................................................................................3-3

Front Control Panel..........................................................................................................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................................................................................................................................3-6

Cooling ................................................................................................................................3-6

Paper Tips...........................................................................................................................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



GBC Pro-Tech 1997 October iii

ORCA-III Operation Manual

Procedure.........................................................................................................................3-8

Encapsulation (With Envelope Feed)..................................................................................3-8

Two-Pass Mount and Laminate (Hot and Cold)...................................................................3-8

Setup................................................................................................................................3-8

Procedure, Pass 1............................................................................................................3-8

Procedure, Pass 2............................................................................................................3-8

Cold/Mount Laminate ..........................................................................................................3-9

With Hot Main Rolls: ........................................................................................................3-9

With Cold Main Rolls:.......................................................................................................3-9

Roll to Roll Transfer and Laminate (One Pass)...................................................................3-9

With Hot Main Rolls: ........................................................................................................3-9

Vinyl Transfer ......................................................................................................................3-9

Roll to Roll Transfer.............................................................................................................3-9

With Hot Main Rolls: ........................................................................................................3-9

Roll to Roll Cold Overlamination (Second Pass Main Rolls Hot) ......................................3-10

With Hot Main Rolls: ......................................................................................................3-10

PROCESS CONTROL CHART 3-1...................................................................................3-11

PROCESS CONTROL DIAGRAM 3-1B.............................................................................3-12

PROCESS CONTROL CHART 3-2...................................................................................3-13

PROCESS CONTROL DIAGRAM 3-2B.............................................................................3-14

PROCESS CONTROL CHART 3-3...................................................................................3-15

PROCESS CONTROL DIAGRAM 3-3B.............................................................................3-16

PROCESS CONTROL CHART 3-4...................................................................................3-17

PROCESS CONTROL DIAGRAM 3-4B.............................................................................3-18

PROCESS CONTROL CHART 3-5...................................................................................3-19

PROCESS CONTROL DIAGRAM 3-5B.............................................................................3-20

PROCESS CONTROL CHART 3-6...................................................................................3-21

PROCESS CONTROL DIAGRAM 3-6B.............................................................................3-22

PROCESS CONTROL CHART 3-7...................................................................................3-23

PROCESS CONTROL DIAGRAM 3-7B.............................................................................3-24

PROCESS CONTROL CHART 3-8...................................................................................3-25

PROCESS CONTROL DIAGRAM 3-8B.............................................................................3-26

PROCESS CONTROL CHART 3-9...................................................................................3-27

PROCESS CONTROL DIAGRAM 3-9B.............................................................................3-28

iv



GBC Pro-Tech 1997 October

ORCA-III Operation Manual

PROCESS CONTROL CHART 3-10 .................................................................................3-29

PROCESS CONTROL DIAGRAM 3-10B...........................................................................3-30

PROCESS CONTROL CHART 3-11 .................................................................................3-31

PROCESS CONTROL DIAGRAM 3-11B...........................................................................3-32

PROCESS CONTROL CHART 3-12 .................................................................................3-33

PROCESS CONTROL DIAGRAM 3-12B...........................................................................3-34

PROCESS CONTROL CHART 3-13 .................................................................................3-35

PROCESS CONTROL DIAGRAM 3-13B...........................................................................3-36

Laminate Temperature Guide and Helpful Hint Sheet for GBC Pro-Tech Products.........3-37

All Pressure Sensitive Materials.....................................................................................3-37

Lamination......................................................................................................................3-37

Mounting ........................................................................................................................3-37

Vinyl Transfer.................................................................................................................3-37

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Cleaning ....................................................................................................................... .......4-1

Adjusting the Main Roll Nip .................................................................................................4-3

Adjusting the Pull Roll Nip...................................................................................................4-4

Chain Tensioning and Take-Up...........................................................................................4-5

Adjusting the Air Cylinder Rate............................................................................................4-6

Lubrication...........................................................................................................................4-8

Contacting Technical Support .............................................................................................4-8

Schematic Diagram.............................................................................................................4-9

Pneumatic Diagram.............................................................................................................4-2

Output Troubleshooting Guide............................................................................................4-9

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Limited Warranty .................................................................................................................5-1

Exclusions to the Wa rranty ..............................................................................................5-1

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Specifications ......................................................................................................................6-1

Illustrated Parts List.............................................................................................................6-2

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

GBC Pro-Tech 1997 October v

ORCA-III Operation Manual Safety

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DO NOT ATTEMPT TO OPERATE YOUR

ORCA-III LAMINATOR UNTIL YOU

HAVE READ THI S S E CT I O N

CAREFULLY!

Your safety, as well as the safety of others, is
important to GBC Pr o- Tech. This section contains
important s afety information.

The following symbols are used t hroughou t this
manua l to indicate warnings and cautions .

DANGER

Indicates an imminently hazardous situation

which, if not avoided, will res ult in death or

serious injury.

WARNING

Indicates a potentially hazardous situation

whic h, if not a voide d , c ould result i n death or

serious injury.

CAUTION

GBC Pro- Tech la minators are powerful machines
that are designed to mount, laminat e and encap sulate.
The forces required t o accomplish thes e tasks can
var y f rom negligible to very large.

The a ir-c ylinder sys tem used to provide downward
pressure on the top roll is capable of producing
forces greater than 1000 pounds (454 kg). This force
is applied to any object pres ent ed in t he op ening
(called the nip) between the two rolls.

Use care in lowering the t op main laminating roll and
know how to r eact qu ic kly in an emergency. The
laminat or roll UP-DOWN s witch is located on t he
instrument panels. This s witch controls t he u p and
down motion of the t op lamina tor roll. B efore
pressing this switch to the DOWN position, ensure
that nothing is in the nip area. If any pr oblem or
danger should occ ur, depr essing any of the
emergency but tons s tops the rolls f rom closing and
ra ises them completely.

Note

⇒

To quickly stop the machine in the event of an
emergency, 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 laminating rolls of the ORCA-III can
reach temperatures of over 200 °F (100 °C). At these
temperatu res t here is a danger of a sever e b urn if the
rolls ar e t ouched during set- up, operation or
servicing.

Indicates a potentially hazardous situation

whic h, if not a voide d , c ould result i n minor or

moderate injury, or alerts against unsafe

practice s, o r ale r t s against ac tions which co uld

damage the product.

The ORCA-III Laminator has been designed with
saf ety as a primary considerat ion. However , you
must b ecome thoroughly familiar with the controls,
proper oper at ion, proper s ervi ce proced ures, a n d
saf ety featur es of the laminator before using or
servicing the unit.



GBC Pro-Tech 1997 October

An important feature of the laminator is the
photoelectric eye sys tem th at st ops the machine wh en
objects move into the nip area.

In “run” mode (forward or revers e arrow is lit
const antly) forward or r everse butt on must b e pushed
for progress to resume.

In “footswit c h” mode (forward or reverse ar row is
flas hing) rolls stop if photoelect ric eye is b loc ked b ut
resu me a utomatica lly when ob struction is removed
from the p hotoelectric eye pa th.

1-1

Safety ORCA-III Operation Manual

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PRO-TECH Engineering Madison,WI 608-246-8844

15

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WARNING

Do not ever attempt to override the

photoelectric eye system. You could be

crushed or severely burned.

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LAMINATOR ROLL CONTROLS

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FAN TABLE

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The ORCA-III Laminator has a steel cabinet that is
bolted closed to isolate the electric al and d rive system
components for the sa f ety of the op erator. Only a
qualif ied s ervice technician shou ld open these
cabinets.

The la mina tor is equipped with two emergency stop
kick cables located on the b ottom front and rear of
the lamina tor and four emergency stop b utt ons
locat ed on the top of either si de of the laminator. Any
of these, if engaged, stop s the la minator. To continue
operation all four emergency stop butt ons must be in
the up position.

Push any button

to stop the

laminator

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to resume

operation - the

button pops up

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Lockout power before
servicing.

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Emergency
Stop Kick
Cable

Figure 1-2: Using the Emergency Stop Kick

Cables

Despite the safety features built into the ORCA-III
La mi nator , ex tr eme cauti o n must be used when
operating or servic ing the unit. READ THE

FOLLOWING WARNINGS AND CAUT IO NS
BEFORE ATTEMPTING TO OPERATE OR
SERVICE THE O RCA-III L AMINATO R.

WARNING

Never place fingers or arms between the rolls

when they are turning or when the rolls are in

the closed position. You can be crushed or

burned.

Figure 1-1: Using the Emergency Stop Buttons

1-2

WARNING

Do not wear ties, loose fi tting cl othi ng o r

dangling jewelry w hile o pe rat ing o r servicing

the laminator. These items can get caught in

the nip and choke you or you can be crushed

or burned.

WARNING

Always use care in lowering the top laminating

roll. You can be crushed or burned.



GBC Pro-Tech 1997 October

ORCA-III Operation Manual Safety

WARNING

Do not operate the laminator near water. You
can be severely shocked, electrocuted or cause

a fire.

DANGER

Remove power from the laminator before

servicing. You can be severely shocked,

electrocuted or cause a fire.

WARNING

Do not use liquid or aerosol cleaners on the

laminator. Do not s pill liquid of any kind on

the laminator. You can be severely shocked,

electrocuted or cause a fire. Use only a damp

cloth for cleaning.

CAUTION

Raise the upper main roll when the laminator

is not in operation. Prolonged contact can

damage the rolls.

CAUTION

Excess pressure can damage the laminating

rolls. Always select the minimum roll pressure

necessary to complete the task.

CAUTION

If silicone adhesiv e c o ntact s the upper or

lower roll, remove it IMMEDIATELY using

80% (o r s tro nger) isopropy l alcohol. It can

harden within an hour and ruin the roll.

WARNING

Exercise care when cleaning the rolls with

80% (o r s tro nger) isopropy l alcohol:

•

Use only in a well ventilated area.

•

Wear rubber gloves.

•

Use only on cool rolls.

Cle aning heated r olls ca n igni te t he fumes .

CAUTION

Use only 80% (o r s tro nger) isopropy l alcohol

or a rubber cement eraser to clean the
laminating rolls. Harsh chemicals like toluene,
acetone or M EK des t r o y the silicone covering

of the rolls.

WARNING

The operating environment must be free of

dust, flammable liquids and vapors. You can

be 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 use a kni fe or other sharp ins trument

during installation or while se r v ic ing t he

laminator. You can cause irreparable damage

to the rolls.



GBC Pro-Tech 1997 October

1-3

Safety ORCA-III Operation Manual

WARNING

Do not attempt to move the laminator across

anything other t han a flat, level surface

without trained and qualified riggers. You can

be crushed or seriously injured.

The ORCA-III Laminator is a large and

heavy piece of equipment. It is necessary to

employ LICENSED RI GG E RS ONLY to

move the machine. The laminator 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 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

laminator improperly.

WARNING

Do not allow anything to rest on the power

cord. Do not locate the cord where people can

walk on it. You or others can be severely

shocked, electrocuted or cause a fire.

WARNING

Never insert objects of any kind through any

of the slots on the laminator. You can touch

dangerous voltage points or short out parts.

You can be severely shocked, electrocuted or

cause a fire.

ALWAYS USE GOOD SAFETY PRACT IC ES
WHEN OPERATING OR SER VICING THE
LAMINATOR AND KNOW HOW TO REACT
QUICKLY IN AN EMERGENCY.

WARNING

Only a qualified electrician should connect

power to the laminator. You can be severely

shocked, electrocuted or cause a fire if power

is improperly applied.

WARNING

Do not operate the laminator if the power

cord is damaged or frayed. You can be

severely shocked, electrocuted or cause a fire.

Contact a qualified electrician to replace the

cord.

1-4



GBC Pro-Tech 1997 October

ORCA-III Operation Manual Safety

&DXWLRQ:DUQLQJ /DEHO /RFDWLRQV

Posted at various locations on your ORCA-III
Laminator are important safety labels. PAY
CAREFUL ATTENTION TO THESE LABELS AT
ALL TIMES! F i gure 1 - 3 shows the location of ea c h
of t h ese label s.



GBC Pro-Tech 1997 October

1-5

Safety ORCA-III Operation Manual

WARNING
ACHTUNG

MISE EN GARDE

WARNING

©1994 HCS, Inc. 800-748-0241 Reorder No.1033R-PT

WARNING
ACHTUNG

MISE EN GARDE

©1994 HCS, Inc. 800-748-0241 Reorder No.1033-PT

DANGER

DANGER
GEFAHR

GEFAHR

HAZARDOUS

HAZARDOUS
VOLTAGE .

VOLTAGE .

To be serviced only

To be serviced only
by trained and

by trained and
authorized personnel.

authorized personnel.
Lockout power before

Lockout power before
servicing.

©1994 Hazard Communication Systems, Inc. 800-748-0241 Reorder No. 5025-PT

©1994 Hazard Communication Systems, Inc. 800-748-0241 Reorder No. 5025-PT

servicing.

(Inside cabinet)

ACHTUNG

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©1994 HCS, Inc. 800-748-0241

Reorder No.1033R-PT

TOP

PRESSURE

40
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HEAT

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PRO-TECH Engineering Madison,WI 608-246-8844

9

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WARNING
ACHTUNG

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by Pro-Tech

DANGER

WARNING

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ACHTUNG

HAZARDOUS

MISE EN GARDE

VOLTAGE.

To be serviced only
by trained and
authorized personnel.
Lockout power before
servicing.

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©1994 HCS, Inc. 800-748-0241 Reorder No. 1012-PT

1-6

WARNING
ACHTUNG

MISE EN GARDE

©1994 HCS, Inc. 800-748-0241 Reorder No.1033R-PT

Figure 1-3: Locations of Safety Labels



GBC Pro-Tech 1997 October

ORCA-III Operation Manual Installation

6HFWLRQ   ,QVWDOODWLRQ

GBC Pro- Tech is c ommitted to a program of ongoing
product improvement. As a result, we are providing
these instructions so that you c an insu re that you r
new ORCA-III Laminator is properly and securely
unpacked, moved and insta lled.

Before an ORCA-III Laminator can be installed there
are a few r equirements t hat mus t be met. Ma k e
certain that each of the requirements listed in the
following pr eins tallation c hecklis t are met befor e
beginning installation.

CAUTION

Do not locate the laminator where air is

blowing directly on the machine. The air flow

can cool the rolls unevenly and result in poor

❒ Have you c ontac ted a certified electricia n to bot h

wire the laminator and ensure that an adequate
power supply, having the appropriate capacity,
overcurr ent pr otection, and saf ety lockout s is
available?
The laminator requires 220 to 240 VAC, 50/60
Hz, 55 A. Or, in Europe only, 3-N phase, 32 A
per phase.

CAUTION

quality output.

Failure to follow the preinstallation checklist

can result in damage to the laminator.

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❒ Are door ways and hallways wide enough f or t he

laminator to be moved to the installation site?

❒ Is there a mple room for the laminator?

A work area mus t be est ablis hed t hat allows for
operation in b oth the front and the r ear of the
machine and p rovides s pac e for effic ient mater ial
flow. Figure 2-1 shows a typical machine area
layout.

❒ Is t he envir onment app ropria te for the laminator?

The la mina tor requires a c lean, du st and vapor
free environment to oper ate properly. I t must not
be located where there is a ir blowing directly on
the machi n e.

WARNING

USA - For singl e pha se 3 wire, tie L 1, L2, an d
L3 t ogether.

Europe - For 3-N phase, L1, L2, and L3 are each
separate phases.

WARNING

Do not operate the laminator if the power

cord is damaged or frayed. You can be

severely shocked, electrocuted or cause a fire.

Contact a qualified electrician to replace the

cord.

WARNING

Do not allow anything to rest on the power

cord. Do not locate the cord where people can

walk on it. You or others can be severely

shocked, electrocuted or cause a fire.

The operating environment must be free of

dust, flammable liquids and vapors. You can
be injured by inhaling chemical vapors. Vapor
build up or stored flammable liquids can cause

a fire. Excessive dust can damage the

laminator.



GBC Pro-Tech 1997 October

2-1

Installation ORCA-III Operation Manual

❒ Is there an appropriate filtered air supply

available?
The lamin ator requires filtered air at 2 cubic feet
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 caus es c orrosion and particles
block pneu ma tic cont rols. Eit her pr oblem can
cause the laminator to malfunction.

It is the cus tomer's responsibilit y to pr ovide
appropriate filters and water traps for the air
hose before the a i r is r o ut ed to the laminato r.
Pro-Tech suggests that the best approach to the
air requirement is to p rovide a dedicated sma ll
compressor for the laminator. A standard light­duty ½ to ¾ horse power (1 kW) electric air
compressor with 1.5 to 2.5 cfm output with a 5
gallon (2 0 liter ) storage tank is appropriate.

CAUTION

The air supply to the laminator must be clean

and dry or the machine will be damaged.

2-2



GBC Pro-Tech 1997 October

ORCA-III Operation Manual Installation

20'

(609 cm)

8'8"

(264 cm)

Supply

2'8"

(81 cm)

Electrical

Supply

Air

4' x 6'

(122 cm x 182 cm)

Work Table

on Wheels

Table Height

35-3/4"

(90.5-91.5 cm)

82" (208 cm)

Rear

Front

Wall

3' (91 cm)

8'8"

(264 cm)

4' x 6'

(122 cm x 182 cm)

Work Table

on Wheels

Table Height

35-3/4"

(90.5-91.5 cm)

13' (396 cm)

Figure 2-1: Laminator Space Requirements



GBC Pro-Tech 1997 October 2-3

Installation ORCA-III Operation Manual

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⇒ NOTE

ALL SHIPMENTS ARE EX- WORKS. At our dock
title passes to the buyer. Please review your
insurance coverage prior to shipment, as you are
responsible for all subsequent freight charges and
risks. Before signing the Bill of Lading you should
be sure to inspect the crate and/or pallet for signs of
damage or missing items; if applicable, make a note
of this on the Bill of Lading.

WARNING

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The unpacking process requires at least two

people. You can be severely injured or

crushed.

Tools required:

• Phillips head screwdriver

7

/8" open end wrench or adju stable wrench

•

To uncrate the laminator:

1. Remove the top of the crate and then the sides in

the order shown in Figure 2-2 .

CAUTION

Do not allow the top to fall into the crate. It

can damage the laminator.

Do not put packing screws on the floor. They

can cause problems when trying to roll the

machine into position.

A second person must support the side labeled

5 in Figure 3-4. It can fall and damage the

laminator.

Figure 2-2: Removing the Crate

2. Carefully unwrap the shrink wrap f rom around

the laminator.

CAUTION

Do not use a kni fe or other sharp ins trument

during installation or while se r v ic ing t he

laminator. You can cause irreparable damage

to the rolls.

3. Ca refully remove any a c c es sories pac ked wit h

the laminator. The accessory pack should
contain:

1 Set, hex wrenches

5

/16" T-handle wrench

1
1 Slitting knife
1 Manual
1 Set, spare fuses
1 Air line qu ic k- c ouple connector, f emale
100% white cotton terry rags

4. Have t he laminator r olled off the skid and plac ed

on the floor by licensed r iggers. The ramps
included with the laminator can be secured to the
edge of the crate b ottom us ing the screws left
over from the crate dis assembly (see Figure 2 - 2).

2-4



GBC Pro-Tech 1997 October

ORCA-III Operation Manual Installation

Before machines leave our loading dock, they are

WARNING

Do not attempt to move the laminator across

anything other t han a flat, level surface

without trained and qualified riggers. You can

be crushed or seriously injured.

pre-treated with a VCI protective film to provide
total corrosion protection. This protective film is
wrapped around the machine and completely sealed.
In addition, moisture absorbing silicone desiccite
packs are packed inside the crate and machine
cabinets.

The ORCA-III Laminator is a large and

heavy piece of equipment. It is necessary to

employ LICENSED RI GG E RS ONLY to

move the machine. The laminator 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 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

laminator improperly.

5. Remove any pl astic strapping and packing paper

taped to the

roll

s.

CAUTION

Do not use a kni fe or other sharp ins trument

during installation or while se r v ic ing t he

laminator. You can cause irreparable damage

to the rolls.

6. Remove all packing mat erials to a saf e dis tance

from the laminator.

⇒

A NOTE ABOUT RECYCLING

The crate components can be reused for shipping
the machine again, or can be disassembled and the
wood and screws recycled. The shrink wrap is not
recyclable, h o wever, s o i t mu s t be d i s ca r ded .

Prior to start up of the machine, you must remove
the desiccite packs from each cabinet and discard.
DO NOT operate the machine with the desiccite
packs inside the cabinets

7. Level the lamina tor u sing the procedure lat er in

this s ection.

6HWXS

Once the ORCA-III Laminator has been unpacked
and moved into final pos ition check ea c h of the
following items.

Tools required:

1

•

/8" hex wrench

•

Adjust able wrench

Setup Procedure

1. Insp ect the la minator for any obviou s shipping

damage.

2. Open t he left and r ight side cabinet c overs wit h

3. Insp ect all the bolts and tighten a ny that were

4. Have a cert if ied electricia n wire the lamina tor

5. Set th e n i p. (See Maintenance for t h e pr o cedure.)

6. Verify that the infra red sensors ar e not blocked.

5

/32" hex wrench by removing the four scr ews

the
holding each cover in plac e.

loosened duri ng shipping.

directly to a power source.

⇒

NOTE

A 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.



GBC Pro-Tech 1997 October

WARNING

NEVER BLOCK T H E I NFRARED

SENSO RS! The rolls can overheat and cause

a fire or seriously damage the laminator.

2-5

Installation ORCA-III Operation Manual

7. Adjust the air cylinder rate. (See Section 4:

Maintenance and Troubleshooting for the

procedure.)

8. Replace both cabinet covers.

/HYHOLQJ

Tools required:

• Adjustable wrench

• Carpenter's level

To lev e l t he laminator:

1. Ra ise each end, remove the cas tors and ins tall a

leveling pad a nd stu d onto each of the foot
brackets at the four bottom corners of the
laminator. T hread t hird nut on st ud ab ove f oot
bracket.

WARNING

Do not lift the wheels more than 3/4" (2 cm.)

above the floor. The leveling pads can become

unstable. You can be crushed.

2. Thread s tud int o 4 leveling pads loc k down with

nut. T hread second nut onto stud.

3. Place a carpenter's level front to rear across the

two lower tie ba rs at one end of the machine .

4. Level this end of the machine fr ont to r ear,

ra ising or lowering the leveling pads by a djusting
the middle nuts on the foot b olts.

5. Move the level to t he other end of t he machine

and level front to rear.

6WDUWXS

The first time the laminator is started and every time
it is s erviced you should use the following checklist to
confirm t hat the unit is op erating properly and that all
saf ety mechanisms ar e functioning.

Startup Checklist

Star t the la minator and go t hrough the following
checklist.

❒ Are the emergency stop but tons working?

Push down on one of the emergency s top b utt ons.
The laminator should stop. Pull up on the but ton
and push t he reset but ton on the lower back of
the lamina tor. The laminator shou ld resu me
operation. Always c hec k all four bu ttons.

WARNING

Never operate the laminator unless both of the

emergency stop buttons are functioning

properly. You can be crushed or burned.

❒ Is t he p hotoelectr i c eye system working?

With t he la minator ru nning and the r olls in the
“up” position, place an object approximately the
size of you r hand just in f ront of the nip on b oth
the fr ont and back of the lamina tor to confirm
that the photoelectric eye system is func tioning.
The
the nip. The lamina tor should r es ume operation if
the machine is in “footswitch” mode. I f the
machine is in “ run” mode, it shou ld be necessa ry
to push the FORWARD or REVE RSE button
to resume roll motion.

s shou ld stop . Move t he ob ject away fr om

roll

6. Place the level direct ly on one of the tie ba rs and

level the machine side to si de.

7. Recheck t he front to rear level condition to ins ure

that it has not c hanged. I f it has, repeat the
leveling procedure.

8. When all the measurements indicate that the

machine is level, tighten down the top nuts on t he
foot b rac kets t o loc k the pads in their current
position.

2-6

WARNING

Never operate the laminator unless the

photoelectric eye system is functioning

properly. You can be crushed or burned.



GBC Pro-Tech 1997 October

ORCA-III Operation Manual Installation

❒ Are the emergency stop kic k c ables working?

With t he laminator r unning, s tep on or kic k the
front emergency stop kick cable. All power
should b e removed from the machine. The rolls
should s top t urning and rise. P ush t he reset
but ton. Restar t the heaters , fa ns, and roll mot ion.
Lower the rolls then repeat the test for the back
emergency stop kick cable.

WARNING

Never operate the laminator unless both of the

emergency stop kick cables are functioning

properly. You can be crushed or burned.

❒ Is t he motor func tioning?

Test the motor at variou s speeds ra nging f rom
0-15. At 0 the
Run the motor in both forwa rd and reverse.

s shou ld stop turning.

roll

❒ Are the hea ters working ?

Verify that the top heater controller heats the top
roll a nd the bottom heater c ontroller heat s the
bottom roll.

Once you ha ve c omplet ed the startup c hecklist you
can safely run a test sample.



GBC Pro-Tech 1997 October

2-7

Installation ORCA-III Operation Manual

Blank Page.

2-8



GBC Pro-Tech 1997 October

ORCA-III Operation Manual Operation

6HFWLRQ   2SHUDWLRQ

6DIHW\

The ORCA-III Laminator has been designed with
saf ety as a primary considerat ion. However , you
must b ecome thoroughly familiar with the controls,
proper oper at ion, proper s ervi ce proced ures, a n d
saf ety featur es of the laminator before using or
servicing the unit.

GBC Pro- Tech la minators a re power ful mac hines
that are designed to mount, laminat e and encap sulate.
The forces required t o accomplish thes e tasks can
var y f rom negligible to very large.

The a ir-c ylinder sys tem used to provide downward
pressure on the top roll is capable of producing
forces greater than 1000 pounds (454 kg). This force
is applied to any object pres ent ed in t he op ening
(called the nip) between the two rolls.

Use care in lowering the top laminat ing roll a nd know
how to r eact qu ic kly in an emergency. The lamina tor
roll UP-DOWN swit c h is located on the inst rument
panels . This switc h c ontrols the up and down motion
of the top laminator roll. Before turning this switch to
the DOWN position, ens ure t hat nothing is in t he nip
area.

In addition, the laminating rolls of the ORCA-III can
reach temperatures of over 200 °F (100 °C). At these
temperatu res t here is a danger of a sever e b urn if the
rolls ar e t ouched during set- up, operation or
servicing.

The ORCA-III Laminator has a steel cabinet that is
bolted closed to isolate the electric al and d rive system
components for the sa f ety of the op erator. Only a
qualif ied s ervice technician shou ld open these
cabinets.

The la mina tor is equipped with fou r emergency stop
buttons located on the top of either side of the
laminator. Any of t hes e, if engaged, stop s the
laminator. To c ontinue oper ation all four emergency
stop buttons must be in the up position.

Push any button

to stop the

laminator

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Figure 3-1: Using the Emergency Stop Buttons

Twist each button

to resume

operation - the

button pops up

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The ORCA-III is equipped with a photoelectric eye
system that stops the machine when objects move into
the ni p a rea.

In “run” mode (forward or revers e arrow is lit
const antly) forward or r everse butt on must b e pushed
for progress to resume.

In “footswit c h” mode (forward or reverse ar row is
flas hing) rolls stop if photoelect ric eye is b loc ked b ut
resu me a utomatica lly when ob struction is removed
from the p hotoelectric eye pa th.

WARNING

Do not ever attempt to override the

photoelectric eye system. You could be

crushed or severely burned.

In addition to the safety features built into the
ORCA-III Laminator, extreme caution must be used
when opera ting or servicing the unit.



GBC Pro-Tech 1997 October

3-1

Operation ORCA-III Operation Manual

In addition, the ORCA-III is equipped with two
Emergency S top Ki c k Cables located at t he lower
front and b ack of the laminator. Either of these, if
stepped on or kicked, st ops the laminat or. To r es tart,
pus h the res et button and reacti vate t he heater s, f ans,
roll motion, and r oll positi on c ontrols .

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PRO-TECH Engineering Madison,WI 608-246-8844

15

9

6

FWD

12

3

AUTO

15
0
18

SPEED

REV

MOTOR CONTROLS

STOP

TOP

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LAMINATOR ROLL CONTROLS

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Emergency
Stop Kick
Cable

Figure 3-4: Emergency Stop Kick Cables

3-2



GBC Pro-Tech 1997 October

ORCA-III Operation Manual Operation

2SHUDWRU &RQWUROV

The operator controls for the ORCA-III Laminator
ar e loc ated on t he front and r ear of the unit, to t he
right of the operator posit i on. T he names and
functions of these controls are as follows:

2SHUDWRU &RQWUROV

The operator controls for the ORCA-III Laminator
ar e loc ated on t he front and r ear of the unit, to t he
right of the operator posit i on. T he names and
functions of these controls are as follows:

)URQW &RQWURO 3DQHO

PRO-TECH Engineering Madison,WI 608-246-8844

Speed Display

Speed Adjust

Upper Heater

Controller

Upper

Heater

ON/OFF

Main Roll Air

Pressure Gauge

Main Roll Air

Pressure

Adjustment

Power

Light

1

9

FWD

6

3

2

0

18

SPEED

MOTOR CONTROLS

3

TOP

1

4

O

ADJ

6

LAMINATOR ROLL CONTROLS

POWER

7

12

15

13

REV

HEAT

PRESSURE

40

20

5

80

100

11

BOTTOM

1

10

O

FAN TABLE

AUTO

12

STOP

ROLL

9

8

Motor REV/REW
Motor Control

Switch

Lower Heater
Controller

Lower
Heater
ON/OFF

Main Roll Up/Down
Switch

Fan/Vacuum
Table ON/OFF

4. UPPER ROLL HEAT O N/O FF - Turns the

heater c ontroller for the top laminati ng roll on or
off.

5. MAIN ROLL AIR PRES S URE G AUG E -

Displays the air pr es sur e p ushing t he main
laminating roll down.

6. MAIN ROLL AIR PRES S URE CO NT RO L -

Varies the air pressure fed to the cylinders that
drive the t op lamina ting r oll down.

7. POWER LIGHT - Indicates when the main

power is b eing applied t o the machine.

8. FAN/VACUUM TABLE ON/OFF - Turns t he

vacu um ta ble on or off.

9. MAIN ROLL UP/DOW N - Sets the main roll

to the u p (loa d) or down ( operate) p osition.

10. LOWER HEAT ON/OFF - Turns th e h eater

contr oller in the bottom lamina ting roll on or off.

11. LOWER HEATER CONTROLLER -

Pr ovides a readou t of t he t emperature of the
bottom laminating roll and the set-point for the
desired temperature. The upper heater must be on
for the lower hea ter t o function.

12. FOOTS W IT CH / CO NT I NUO US RUN -

Changes control of t he mac hine drive from t he
foots witch to continuou s ru n.

13. MOT IO N CO NT RO L FORWARD/STOP

REVERSE - Controls t he direction of the drive
system - forward, stop, or revers e.

Figure 3-1: Front Control Panel

1. SPEED DISPLAY - Provides digit al readout of

the machi n e speed and tot al throug h put in ei ther
metric or st andard unit s.

2. SPEED ADJUSTMENT - Adjusts the speed of

th e machin e from z e ro to maximum a s the c ontr ol
is tu rned clockwis e.

3. UPPER HEATER CONTROLLER - Provides

a readout of the temperature of the upper
laminating roll and the set-point for the desired
temperature.



GBC Pro-Tech 1997 October

3-3

Operation ORCA-III Operation Manual

5HDU &RQWURO 3DQHO

PRESSURE

40

20

Pull Roll Clutch Air

Pressure Gauge

Pull Roll Clutch

Air Pressure

Adjustment

Pull Roll Air

Pressure Gauge

Pull Roll Air

Pressure

Adjustment

Cooling Fans

ON/OFF

80

1

100

ADJ

2

PULL ROLL CLUTCH

PRESSURE

40

20

80

3

100

ROLL

ADJ

4

PULL ROLL CONTROLS

COOLING FANS

AUTO

5

6

STOP

8

7

Pull Roll
Clutch
ON/OFF

Pull Roll
Up/Down
Switch

Motor Control
Switch

Figure 3-2: Rear Control Panel

1. PULL ROLL CLUTCH PRESSURE

GAUGE - M easures and displays t he air

pres sur e driving the pull roll clutch, which sets
web tension.

6HWXS

Setup of the ORCA-III Laminator is quick and
straightfor ward when instruct ions are followed
exactly.

CAUTION

Always use the same shim settings on the left

and right side of the laminator.

To adj ust t h e n i p pl eas e see Section 4: Maintenance
and Troubleshooting.

/DPLQDWRU 5ROO 3UHVVXUH

Use only the minimum amount of roll pressure
needed to accomplis h the task. While higher pres sur e
can ma ke t he adhesive bond f aster, exces s pr essure
can damage the rolls. Wrinkles and bubbles have
cau ses that gener ally cannot be c ured by app l ying
more pressure.

2. PULL ROLL CLUTCH AIR PRESSURE

ADJUSTMENT - Adjusts the clutch pressure
from z e ro to maximum a s the control is turned
clockwise.

3. PULL ROLL AIR PRES S URE G AUG E -

Meas ures and disp lays the air pres sur e p ushing
the pull roll down.

4. PULL ROLL AIR PRES S URE

ADJUSTMENT- Varies the air pressure fed to
the cylinders that drive t he pull roll down.

5. COOLING FANS ON/OFF- Tu rns the cooling

fans on or of f .

6. FOOTSWITCH / CO NT I NUO US RUN -

Changes control of t he mac hine drive from t he
foots witch to continuou s ru n.

7. PULL ROLL UP/DOWN - Sets the pull roll to

the up ( load) or down (operate) position.

8. PULL ROLL CLUTCH ON/OFF- Tur ns t he

pull roll clut c h on or off.

CAUTION

Excess pressure can damage the laminating

rolls. Minimum laminator roll pressure is

consistent with good results.

A typical roll pressure for soft substrates such as
Foamcore or Orca-Board is between 20 to 30 pounds
per square inch (PSI) or 140 to 205 kPa.

The r ange of typ ic al values for hard subst rates is 25
to 50 PSI or 170 to 345 kPa.

3-4



GBC Pro-Tech 1997 October

ORCA-III Operation Manual Operation

/RDGLQJ WKH )LOP

Film is loa ded on t he appropriate unwinds. Loading
and a ligning the film ar e dis c ussed later in this
section. For ap plications s uch as encap sula tion, f ilm
is fed from both t he top a nd bott om feed unwinds .

The process of loading and aligning film is t he s ame
for both the top and the bottom unwinds. There are
two import ant p oints t o remember when loading film:

1. The a dhesive side of t he film mus t be or ient ed

away ( on the outside) fr om the laminating roll.
Otherwise it will immediately bond to the roll,
creating a major c lean-up pr oject.

Films ha ve a shiny side and a du ll side. The dull
side is t he one with the adhesi ve. The du ll side
should ALWAYS face outward from the
laminating roll.

CAUTION

Always mount the film so that the adhesive

side faces outward from the laminating roll.

This prevents hours of roll cleaning.

2. Th e film must be centered on t h e unwind for best

performance. This is vital when two films are fed
together . If the two films are not aligned, f eed
problems, wrinkles a nd other assorted trou bles
will occur .

3RVLWLRQLQJ WKH )LOP

The following procedur e is app licable t o all the feed
unwinds.

Tools required:

5

/16" T-handle wrench

•

• Tape measure

To position the film:

1. Open t he top unwind by removing the p in and

swinging the a rm out.

2. Position the film chuck with the brake on the left

side of the arm. Make sure that the brake piston
is fully retracted (pu shed in).

3. Load t he film.

4. Center the film on the u nwind arm b y measuring

the distance form the ends of the film to the sides
of the machine using a tape measure.

5. Lock down t he c huck on the right side using the

5

/16" T-handle wrench supplied with your
laminator. Mount a rubber O-ring on the left side
of the film, followed by a film chuck. Be sure
that the collar only touches , bu t does not tighten,
the O-ring.

6. Ti g h ten t h e screw on the brake chuck.

7. Recheck the cent ering of the film roll with the

tape measure. Readjust if necessary.

8. Return the arm to its locked position and reinsert

the locking pin.

CAUTION

Carefully align the two films being fed into the

nip. If not, y o u will o bt ain poo r r e s ults .



GBC Pro-Tech 1997 October

3-5

Operation ORCA-III Operation Manual

+HDWLQJ

Use the following instructions when heating one or
both of the laminating rolls. The pr oc edure is t he
same for the top and bottom heaters.

1. Set the heater switch to ON.

2. Adjust the t emper at ur e cont roller for the desired

opera ting temperatur e usi n g the temperatu re
controller push b u ttons.

3. For the Syrlec type controller, use the up and

down arrows to adjust the set point. Hold down
the required arrow until the correct set point is
acheived.
For the CAL3200, it is necessary to press the
star button at the same time as the up or down
arrow to adjust the set point temperature.

4. When heating the rolls, keep t h e top rol l d ow n

and t urning at a modera te speed t o prevent
uneven heating.

5. It will t ake ap prox ima tely 25 minutes for the

laminating roll(s) to reac h op erating temperatu re.
When the pres et operating tempera tu re has been
reac hed, the mac hine is ready to use.

3DSHU 7LSV

1. Always c ut t he lea ding edge of a print s traight so

it ca n be fed perp endicular to t he laminating roll.

2. If you ar e laminat ing very thin p aper s, you

should consider utilizing the ORCA III's envelope
feed. This pa tented techniqu e is the best c hoic e
for the output from electrostatic printers that
have signif i c ant water cont ent or for paper s with
excessive stretch.

6. The ORCA-III can be used for cold mounting

and la mina ting while maintaining the temperat ure
of the main la minating rolls by using the ou tput
rolls as a lamina tor ( by feeding prints from the
rear) f or a quick change-over b et ween hot and
cold laminating.

&RROLQJ

The following is the fastest way to cool down the
machine.

1. Set th e h eater switches to OFF.

2. Position the two rear air tubes so that they are

tilted to direct air flow at the rolls.

3. Set the Laminator Roll Control to the DOWN

position.

4. Set the Forward/Reverse switch to the

FORWARD posit on.

5. Set the speed control to 5 fpm (150 cpm).

6. Let t he machine run until the lamina ting rolls

return to room temperature.

3-6



GBC Pro-Tech 1997 October

ORCA-III Operation Manual Operation

3URFHVV&RQWURO&KDUWV

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-III 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, Orca-Board and
typical prints.

0RXQWLQJ2QO\

6HWXS

1. See process charts 3-1, 3-2 and diagram 3-2b.

2. Shims: Set to the thickness of the material being

used for mounting.

3. Upper Laminator Roll Pressure: 40 P SI (275

kPa).

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. Put a piece of con tact/release paper over the

print. 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/Orca-Board package through the

nip.

0RXQWLQJ/DPLQDWLQJ

The following procedure is for one-step mounting and
heat-activated laminating using mounting board with
one adhesive side (such as Orca-Board).

6HWXS

1. See process chart 3-3 and diagram 3-3b.

2. Mount the film and web as shown in diagram

3-3b.

1

3. Shims: Set the two front shim dials to

than board thickness.

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

5. Speed: 3 fpm (90 cpm).

6. Upper Laminator Roll Heat: 230 °F (110 °C).

7. Cooling: Off

8. Film Tension: Minimum amount needed to have

the film lay smooth, about half way up the roll,
on the upper main roll. Generally one to two
turns on the unwind brake.

3URFHGXUH

Feed the Orca-Board dull (adhesive) side up with the
print positioned as desired. A tack iron can be used to
hold the leading edge of the print in place.

/32" less

4. Speed: 3 fpm (90 cpm).

5. Upper Laminator Roll Heat: 230°F (110 °C).



GBC Pro-Tech 1997 October

3-7

Operation ORCA-III Operation Manual

(QFDSVXODWLRQ

6HWXS

1. See process chart 3-4 and diagram 3-4b.

2. Shims: None.

3. Front Laminat ing Roll Pressure: 80 PSI

(550 kPa).

4. Back P ull Roll Clu tch Pressure: On, 8 0 PS I

(550 kPa).

5. Pull Roll: Down, Pressu re - 80 PSI ( 550 kPa).

6. Speed: 5-7 fpm (150-210 cpm).

7. Upper Laminator Roll Heat: 220-230 °F

(104-110 °C).

8. Lower Laminator Roll Heat: 220-230 °F

(104-110 °C).

9. Cooling: Optional

10. Use of the r ear wind-up roll for the fi n i shed

mater ial is op tional. It is a good p rocedure for
long runs.

6HWXS

1. See process charts 3-5, 3-6, 3-7, and 3-8 and

diagrams 3-5b, 3-6b, 3-7b, and 3-8b for film
mounting instructions and ma c hine adjustments.

2. Ensure that the mounting film from the bottom

side has the sticky (adhesive) side riding up
ar ound the outside of t he b ottom la mina ting r oll.

3URFHGXUH 3DVV 

1. Run the print t hrough to apply adhesive and

laminate.

2. Trim to slightly larger t han the desired finished

size.

3URFHGXUH 3DVV 

1. Prepare to p ut t he p rint through a s econd time to

mount the print to the substrate - anything from
wood, t o Masinote, to Gator foam. Start by
setting the shims to the appropriate spacing for
the material used.

2. Trim the board to the size of the print.

3URFHGXUH

Feed the work into the nip with the leading edge tight
and entering the nip evenly from side to s ide. For thin
pap er fr om electrost atic print ers in roll form it is best
to fold over the leading edge approx imately 6 inches
to cr eate a squa re leading edge.

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)HHG

The us e of th e en v el o pe feed featu re greatly
simplifies the input of lar ge ha nd- fed prints. The
proc edure is identical to that f or regu lar
encapsulation ( see above), h ow ev er, the mach i n e
setup is diff erent as shown in proc es s chart 2-5 and
diagram 2-5B

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There ar e severa l ap proa ches to the moun t/ l aminat e
task. I t ca n be accomplished with either hot or cold
laminate film on the top. Also, the second pass f or
mounting can be done by f eeding from either the fr ont
or back of the laminator.

3. Align the wor k to the boar d and ensu re an ex act

fit. Place weights on the center of t he p rint to
make sure tha t it does not move relat i ve t o the
board during t he next st eps.

4. Ra ise one end of the print and peel ba c k

approx i mat ely two inches of the li n er t o expo se
the adhesive that was applied to the print in the
first pass . Fold it under .

5. Lay t h e pr i n t b ack d ow n even ly a nd ext remely

flat. From t he c ent er outward, tac k the expos ed
adhesive to the substrate.

6. Position the pi ece so that the end with the liner

peeled ba ck is fa cing the nip. Insert the first one
inch of the board into the nip. Very carefully
wrap the print back and over the top laminating
rol l . Be sure t h ere ar e no wrink l es in the nip a rea.
Car eful l y peel of f th e l i n er as the b o ard
progress es through the la minator .

7. Trim the p i ece to the f i n i shed size.

3-8



GBC Pro-Tech 1997 October

ORCA-III Operation Manual Operation

&ROG0RXQW /DPLQDWH

:LWK +RW 0DLQ 5ROOV

1. See process chart 3-8 and diagram 3-8b for film

mounting instructions and machine adjustments.

2. Move the feed table to the rear of the laminator.

3. Ra ise the main roll ( hot).

The blades on both the infeed and outfeed

slitters are razor sharp. You can cut yourself

9LQ\O 7UDQVIHU

WARNING

severely.

4. Reverse the motor.

5. Web a c c ording to drawing.

6. Set the nip height and tack the lea ding edge for

the second pass . Run thr ough as the liner is being
pulled off.

:LWK &ROG 0DLQ 5ROOV

1. See process chart 3-9 and diagram 3-9b for film

mounting instructions and machine adjustments.

2. Use the machine as a cold laminator with the

main rolls not heat ed.

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1. See process chart 3-10 and diagram 3-10b for

film mounting inst ructions and machine
adjustments.

2. Web the vinyl over the bottom roll and hold with

the pull r olls.

3. It is useful to have a leader on the paper so it can

be webbed t hrough and taped t o the rewind
befor e s tarti ng.

4. Lower the main roll, start the motor, and begin

the tr ansfer proc ess . Ta pe th e finished pro d uct to
the rewind and add t he laminat ion by raising the
pull roll. Web the laminate around the upper pull
roll. Be sure it is smooth on the roll, t hen lower
the roll.

5. Add infeed a n d o ut feed sl itter s a s needed.

1. See process chart 3-11 and diagram 3-11b for

film mounting inst ructions and machine
adjustments.

2. Web the vinyl u p ar ound the bot tom main roll

and over to the pu ll roll. Make s ure the material
is webbed straight and lower t he pull roll to hold
the vinyl.

3. Place both table idlers in the slots on the table

bracket s. Web the paper through a s shown in
diagram 2-11b.

4. Oft en, when paper is not on a c ore, hand tension

must b e applied t o the paper in order t o ma intain
transf er qua lity unt il the end of the trans f erred
image.

5ROO WR 5ROO 7UDQVIHU

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1. See process chart 3-12 and diagram 3-12b for

film mounting inst ructions and machine
adjustments.

2. Web the vinyl u p ar ound the bot tom main roll

and over to the pull roll. Lower the pull roll t o
hold the vinyl.

3. Web the paper up to the main roll. Lower the

main roll to start the transfer process.

4. Tape t he vinyl ont o the lower rewind and p eel off

the paper. Wind it on the upper rewind.

5. La mina tion can be done in a s econd pass, if

required. See cha rt 2- 13.



GBC Pro-Tech 1997 October

3-9

Operation ORCA-III Operation Manual

5ROO WR 5ROO &ROG 2YHUODPLQDWLRQ
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1. See process chart 3-12 and diagram 3-13b for

film mounting inst ructions and machine
adjustments.

2. Install the brake adapter on the rear rewind.

3. Bring the vinyl up over the bot tom lamination

roll a nd throu gh the main rolls.

4. Tape the overlaminate release liner to the upper

rewind.

5. Web the overlaminate material around the upper

pull roll and lower it to begin over l amination.

3-10



GBC Pro-Tech 1997 October

ORCA-III Operation Manual Operation

352&(66 &21752/ &+$57 

Product:__________________Process:_________________________Date: _____________
Material Top:___________________________Material Bottom:________________________
Other Material: ______________________________________________________________

FRONT CONTROL SETTINGS

Speed (Ft/min): Reverse/Forward:

Roll Up/Down: Shim Dial:

Roll Pressure: Top Temp. Set:

Top Heater On /Off: Bottom Temp. Set:

Bottom Heater On/Off:

REAR CONTROL SETTINGS

Pull Clutch On/Off: Pull Roll Up/Down:

Pull Clut ch Pressur e: Pull Roll Pressure:

Shim Dial: Cooling:

See Chart 3-1B for Webbing Outline

Special Instructions: __________________________________________________________

__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________



GBC Pro-Tech 1997 October

3-11

Operation ORCA-III Operation Manual

352&(66 &21752/ ',$*5$0 %

IDENTIFICATION DI AGRAM

(I) Removable Idler
(F) Fixed Idler
(U) Unwind Shaft
(R) Rewind
(M) Main Roll
(P) Pull Roll
(C) Cooling Tube
(S) Slitter Idler

Small Table

Infeed Slitter

S

R

I

I

F

F

M

I I I

M

U

R

Outfeed Slitter

C

P

I

P

C

I

Large Table

R

U

U

S

F

F

R

U

U

Outfeed Slitter

3-12

 GBC Pro-Tech 1997 October

ORCA-III Operation Manual Operation

352&(66&21752/&+$57

Product:__________________Process:_1-Pass Mounting_________Date:_______________
Material Top:___________________________Material Bottom:_3/16 inch Orca-Board_____
Other Material:______________________________________________________________

FRONT CONTROL SETTINGS

Speed (Ft/min): 3 (90 cm/min) Reverse/Forward: Forward

Roll Up/Down: Down Shim Dial: 3/16 (.48 cm)

Roll Pressure (psi): 40 Top Temp. Set: 230 °F, 110 °C

Top Heater On/Off: On Bottom Temp. Set: 32 °F, 0 °C

Bottom Heater On/Off: On

REAR CONTROL SETTINGS

Pull Clutch On/Off: -- Pull Roll Up/Down: Up

Pull Clutch Pressure (psi): -- Pull Roll Pressure (psi): --

Shim Dial: -- Cooling: No

See Chart 3-2B for Webbing Outline

Special Instructions:__________________________________________________________

__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________



GBC Pro-Tech 1997 October

3-13

Operation ORCA-III Operation Manual

352&(66 &21752/ ',$*5$0 %

ONE PASS MOUNT (HEAT ACTIVATED ADHESIVE)

Use release
liner if print is
heat sensitive

Hot

Dial Nip

Height

Print

Orca-Board

Hot or

Cold

3-14



GBC Pro-Tech 1997 October

ORCA-III Operation Manual Operation

352&(66&21752/&+$57

Product:_Orca-Board________Process:_One Pass Mount and Laminate__Date:__________
Material Top:__3 Mil Gloss______________Material Bottom:_3/16 inch Orca-Board________
Other Material:______________________________________________________________

FRONT CONTROL SETTINGS

Speed (Ft/min): 3 (90 cm/min) Reverse/Forward: Forward

Roll Up/Down: Down Shim Dial: 3/16 (.48 cm)

Roll Pressure (psi): 40 Top Temp. Set: 230 °F, 110 °C

Top Heater On/Off: On Bottom Temp. Set: 32 °F, 0 °C

Bottom Heater On/Off: On

REAR CONTROL SETTINGS

Pull Clutch On/Off: -- Pull Roll Up/Down: Up

Pull Clutch Pressure (psi): -- Pull Roll Pressure (psi): --

Shim Dial: -- Cooling: No

See Chart 3-3B for Webbing Outline

Special Instructions:__________________________________________________________

__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________



GBC Pro-Tech 1997 October

3-15

Operation ORCA-III Operation Manual

352&(66 &21752/ ',$*5$0 %

ONE PASS MOUNT AND LAMINATE

Over-

laminate

Hot

Print

Orca-Board

Dial Nip

Height

Hot or

Cold

3-16



GBC Pro-Tech 1997 October

ORCA-III Operation Manual Operation

352&(66 &21752/ &+$57 

Product:___________________Process:_Encapsulation______________Date: ___________
Material Top:__3 Mil Gloss______________Material Bottom:_3 Mil Gloss___ _____________
Other Material: ______________________________________________________________

FRONT CONTROL SETTINGS

Speed (Ft/min): 3-5 (90-152 cm/min) Reverse/Forward: Forward

Roll Up/Down: Down Shim Dial: 0

Roll Pressure (psi): 80 Top Temp. Set: 220 °F, 104 °C

Top Heater On/Off: On Bottom Temp. Set: 220 °F, 104 °C

Bottom Heater On/Off: On

REAR CONTROL SETTINGS

Pull Clutch On/Off: On Pull Roll Up/Down: Down

Pull Clut ch Pressur e (psi): 80 Pull Roll Pressure (psi): 80

Shim Dial: 0 Cooling: On

See Chart 3-4B for Webbing Outline

Special Instructions: __________________________________________________________

__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________



GBC Pro-Tech 1997 October

3-17

Operation ORCA-III Operation Manual

352&(66 &21752/ ',$*5$0 %

ENCAPSULATION

10 Mil Film

Laminate

Web Film Underneath
This Idler When Using

DETAIL

10 Mil Film (See Detail)

Optional Outfeed
Slitter

Optional

Infeed Slitter

Paper

Optional

Laminate

Hot

Hot

Laminate

Large Table

Optional
Outfeed Slitter

Optional
Rewind

Optional

Laminate

3-18



GBC Pro-Tech 1997 October

ORCA-III Operation Manual Operation

352&(66&21752/&+$57

Product:___________________Process:_Encapsulation (Envelope Feed) Date:___________
Material Top:__3 Mil Gloss______________Material Bottom:_3 Mil Gloss___ _____________
Other Material:______________________________________________________________

FRONT CONTROL SETTINGS

Speed (Ft/min): 2-3 (90-122 cm/min) Reverse/Forward: Forward

Roll Up/Down: Down Shim Dial: 0

Roll Pressure (psi): 80 Top Temp. Set: 230 °F, 104 °C

Top Heater On/Off: On Bottom Temp. Set: 230 °F, 104 °C

Bottom Heater On/Off: On

REAR CONTROL SETTINGS

Pull Clutch On/Off: On Pull Roll Up/Down: Down

Pull Clutch Pressure ( psi) : 80 Pull Roll Pressure ( psi): 80

Shim Dial: 0 Cooling: --

See Chart 3-5B for Webbing Outline

Special Instructions:__________________________________________________________

__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________



GBC Pro-Tech 1997 October

3-19

Operation ORCA-III Operation Manual

352&(66 &21752/ ',$*5$0 %

ENCAPSULATION (ENVELOPE FEED)

Laminate

Print

Optional

Laminate

Hot

Hot

Laminate

Optional
Outfeed Slitter

Optional
Rewind

Optional

Laminate

3-20



GBC Pro-Tech 1997 October

ORCA-III Operation Manual Operation

352&(66&21752/&+$57

Product:___________________Process:_Two Pass Mount & Laminate (1st Pass) Date:____
Material Top:__3 Mil Gloss______________Material Bottom:_ Pressure Sensitive Film ___ __
Other Material:______________________________________________________________

FRONT CONTROL SETTINGS

Speed (Ft/min): 3-7 (90-213 cm/min) Reverse/Forward: Forward

Roll Up/Down: Down Shim Dial: 0

Roll Pressure (psi): 80 Top Temp. Set: 220 °F, 104 °C

Top Heater On/Off: On Bottom Temp. Set: 32 °F, 0 °C

Bottom Heater On/Off: On

REAR CONTROL SETTINGS

Pull Clutch On/Off: On Pull Roll Up/Down: Down

Pull Clutch Pressure ( psi) : 80 Pull Roll Pressure ( psi): 80

Shim Dial: 3/16 (.48 cm) Cooling: --

See Chart 3-6B for Webbing Outline

Special Instructions:__________________________________________________________

__________________________________________________________________________
__________________________________________________________________________



GBC Pro-Tech 1997 October

3-21

Operation ORCA-III Operation Manual

352&(66 &21752/ ',$*5$0 %

TWO PASS MOUNT AND L AMINATE (FIRST PASS)

Laminate

Optional Outfeed
Trim Rewind

Optional
Outfeed
Trim

Paper Sheet

Feed Hand

Wind on Core

(Tip! - Keep

Leading Edge

Straight-

Parallel to Roll)

Hot

Cold

Optional Paper

on Core

Optional Infeed

Trim Rewind

Optional

Mount

Adhesive

Mount

Adhesive

Optional

Mount

Adhesive

Optional
Outfeed Trim

Optional
Rewind of
Finished
Product

3-22



GBC Pro-Tech 1997 October

ORCA-III Operation Manual Operation

352&(66 &21752/ &+$57 

Product:___________________Process:_Two Pass Mount & Laminate (2nd Pass) Date: ____
Material Top:__ ______________Material Bottom:_ 3/16 Foamcore ___ _____________
Other Material: ______________________________________________________________

FRONT CONTROL SETTINGS

Speed (Ft/min): 0-7 (0-213 cm/min) Reverse/Forward: Reverse

Roll Up/Down: Up Shim Dial: 3/16

Roll Pressure (psi): -- Top Te mp. Set: --

Top Heater On/Off: On/Off Bottom Temp. Set: --

Bottom Heater On/Off: Off

REAR CONTROL SETTINGS

Pull Clutch On/Off: On Pull Roll Up/Down: Down

Pull Clutch Pressure (psi): 80 Pull Roll Pressure (psi): 20-50

Shim Dial: 3/16 (.48 cm) Cooling: --

See Chart 3-7B for Webbing Outline

Special Instructions: __________________________________________________________

__________________________________________________________________________
__________________________________________________________________________



GBC Pro-Tech 1997 October

3-23

Operation ORCA-III Operation Manual

352&(66 &21752/ ',$*5$0 %

TWO PASS MOUNT AND L AMINATE (SECOND PASS)

Can Use Main

Rolls If Cold

If Hot

Dial Nip

Height

Running
Positions

Release Liner

Tack Lead-In
Edge to Board

Starting
Positions

Release Liner
Orca-Board

Shim Dial

3-24



GBC Pro-Tech 1997 October

ORCA-III Operation Manual Operation

352&(66 &21752/ &+$57 

Product:___________________Process:_Cold Mount/Laminate Date: ______________
Material Top:_1 Mil Gloss________________Material Bottom:_Promount___ _____________
Other Material: ______________________________________________________________

FRONT CONTROL SETTINGS

Speed (Ft/min): 0-14 (0-430 cm/min) Reverse/Forward: Reverse

Roll Up/Down: Up Sh im Dial: 0

Roll Pressure (psi): -- Top Te mp. Set: --

Top Heater On /Off: -- Bottom Temp. Set: --

Bottom Heater On/Off: --

REAR CONTROL SETTINGS

Pull Clutch On/Off: On Pull Roll Up/Down: Down

Pull Clut ch Pressur e (psi): 80 Pull Roll Pressure (psi): 80

Shim Dial: 0 Cooling: --

See Chart 3-8B for Webbing Outline

Special Instructions: __________________________________________________________

__________________________________________________________________________

__________________________________________________________________________________________

__________________________________________________________________________



GBC Pro-Tech 1997 October

3-25

Operation ORCA-III Operation Manual

352&(66 &21752/ ',$*5$0 %

COLD MOUNT/LAMINATE

(WHEN MAIN ROLLS ARE HOT, ELIMATES COSTLY HEAT-UP AND COOL-DOWN TIME)

Cold

Laminate

Hot

Optional

Mount

Adhesive

Hot

Mount

Adhesive

Optional

Mount

Adhesive

3-26



GBC Pro-Tech 1997 October

ORCA-III Operation Manual Operation

352&(66 &21752/ &+$57 

Product:___________________Process:_Cold Lamination_________Date: ______________
Material Top:__1 Mil Pressure Sensitive Laminate___Material Bottom:_Promount __________
Other Material: ______________________________________________________________

FRONT CONTROL SETTINGS

Speed (Ft/min): 0-14 (0-430 cm/min) Reverse/Forward: Forward

Roll Up/Down: Down Shim Dial: 0

Roll Pressure (psi): 80 Top Temp. Set: --

Top Heater On/Off: Off Bottom Temp. Set: --

Bottom Heater On/Off: Off

REAR CONTROL SETTINGS

Pull Clutch On/Off: On Pull Roll Up/Down: Down

Pull Clut ch Pressur e (psi): 80 Pull Roll Pressure (psi): 80

Shim Dial: 0 Cooling: --

See Chart 3-9B for Webbing Outline

Special Instructions: __________________________________________________________

__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________



GBC Pro-Tech 1997 October

3-27

Operation ORCA-III Operation Manual

352&(66 &21752/ ',$*5$0 %

COLD LAMINATION

Pressure
Sensitive
Laminate

Paper

Cold

Optional

Infeed Slitter

Optional Paper

Wound on Core

Optional

Edge Trim

Rewind

Cold

Mount

Adhesive

Optional
Outfeed
Slitter

Optional
Rewind

3-28



GBC Pro-Tech 1997 October

ORCA-III Operation Manual Operation

352&(66&21752/&+$57

Product:_______________Process:_Roll Transfer & Laminate “One Pass”_Date:__________
Material Top:__3M Vinyl Overlaminate_Material Bottom:_3M Vinyl Transfer Material _______
Other Material:__Transfer Paper ________________________________________________

FRONT CONTROL SETTINGS

Speed (Ft/min): 1.5-2.5 (46-76 cm/min) Reverse/Forward: Forward

Roll Up/Down: Down Shim Dial: All t he way up

Roll Pressure (psi): 90 Top Temp. Set: 290 °F, 140 °C

Top Heater On/Off: On Bottom Temp. Set: 32 °F, 0 °C

Bottom Heater On/Off: On

REAR CONTROL SETTINGS

Pull Clutch On/Off: On Pull Roll Up/Down: Down

Pull Clutch Pressure ( psi) : 50 Pull Roll Pressure ( psi): 80

Shim Dial: 0 Cooling: On

See Chart 3-10B for Webbing Outline

Special Instructions:__________________________________________________________

__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________



GBC Pro-Tech 1997 October

3-29

Operation ORCA-III Operation Manual

352&(66 &21752/ ',$*5$0 %

ROLL TRANSFER AND LAMINATE “ONE PASS”

(SLITTING INFEED AND OUTFEED)

Overlaminate

Rewind

Transfer

Paper

Hot

Transfer

Paper Infeed

Trim

Cold

Rewind
Laminate
Paper

Transfer Paper

Unwind

Transfer

Paper
Cutoff

Rewind

Optional

Vinyl

Vinyl

Outfeed Trim

Rewind of
Finished
Product

Optional

Vinyl

3-30



GBC Pro-Tech 1997 October

ORCA-III Operation Manual Operation

352&(66&21752/&+$57

Product:___________________Process:_Transfer Paper Wound on Itself_Date:__________
Material Top:___________________________Material Bottom:_3M Vinyl___ _____________
Other Material:___Transfer Paper _______________________________________________

FRONT CONTROL SETTINGS

Speed (Ft/min): 1.5-2.5(76 cm/min) Reverse/Forward: Forward

Roll Up/Down: Down Shim Dial: All t he way up

Roll Pressure (psi): 90 Top Temp. Set: 290 °F, 140 °C

Top Heater On/Off: On Bottom Temp. Set: 32 °F, 0 °C

Bottom Heater On/Off: On

REAR CONTROL SETTINGS

Pull Clutch On/Off: On Pull Roll Up/Down: Down

Pull Clutch Pressure ( psi) : 50 Pull Roll Pressure ( psi): 80

Shim Dial: 0 Cooling: On

See Chart 3-11B for Webbing Outline

Special Instructions:__________________________________________________________

__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________



GBC Pro-Tech 1997 October

3-31

Operation ORCA-III Operation Manual

352&(66 &21752/ ',$*5$0 %

Transfer

Paper

Optional

Vinyl

Hot

Cold

Optional

Vinyl

Vinyl

3-32



GBC Pro-Tech 1997 October

ORCA-III Operation Manual Operation

352&(66&21752/&+$57

Product:___________________Process:_Roll to Roll Transfer_________Date:___________
Material Top:___________________________Material Bottom:_3M Vinyl___ _____________
Other Material:___Transfer Paper _______________________________________________

FRONT CONTROL SETTINGS

Speed (Ft/min): 1.5-2.5(76 cm/min) Reverse/Forward: Forward

Roll Up/Down: Down Shim Dial: All t he way up

Roll Pressure (psi): 90 Top Temp. Set: 290 °F, 140 °C

Top Heater On/Off: On Bottom Temp. Set: 32 °F, 0 °C

Bottom Heater On/Off: On

REAR CONTROL SETTINGS

Pull Clutch On/Off: On Pull Roll Up/Down: Down

Pull Clutch Pressure ( psi) : 50 Pull Roll Pressure ( psi): 80

Shim Dial: 0 Cooling: On

See Chart 3-12B for Webbing Outline

Special Instructions:__________________________________________________________

__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________



GBC Pro-Tech 1997 October

3-33

Operation ORCA-III Operation Manual

352&(66 &21752/ ',$*5$0 %

ROLL-TO-ROLL TRANSFER

3-34



GBC Pro-Tech 1997 October

ORCA-III Operation Manual Operation

352&(66 &21752/ &+$57 

Product:___________________Process:_Roll to Roll Cold Overlamination Date: __________
Material Top:_Pressure Sensitive Overlaminate_ Material Bottom:_Transfer Material ___ ____
Other Material:___ ___________________________________________________________

FRONT CONTROL SETTINGS

Speed (Ft/min): 0-14 (0-430 cm/min) Reverse/Forward: Reverse

Roll Up/Down: Up Shim Dial: --

Roll Pressure (psi): -- Top Te mp. Set: --

Top Heater On /Off: -- Bottom Temp. Set: --

Bottom Heater On/Off: Off

REAR CONTROL SETTINGS

Pull Clutch On/Off: On Pull Roll Up/Down: Down

Pull Clut ch Pressur e (psi): 80 Pull Roll Pressure (psi): 80

Shim Dial: 0 Cooling: No

See Chart 3-13B for Webbing Outline

Special Instructions: __________________________________________________________

__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________



GBC Pro-Tech 1997 October

3-35

Operation ORCA-III Operation Manual

352&(66 &21752/ ',$*5$0 %

ROLL TO ROLL COLD OVERLAMINATION

Pressure
Sensitive
Overlaminate

Edge Trim

Rewind

Hot

Infeed Slitter

Now Becomes

Outfeed Slitter

Cold

Rewind
Laminate
Paper

Rewind of

Finished

Product

Transferred
Image On
Vinyl

Add
Brake
Pad

3-36



GBC Pro-Tech 1997 October

ORCA-III Operation Manual Operation

/DPLQDWH 7HPSHUDWXUH *XLGH DQG +HOSIXO +LQW
6KHHW IRU *%& 3UR7HFK 3URGXFWV

HOT LAMINATES

FILM TEMP SPEED

Bond Paper, E-Stat, etc./Ink Jet

3 MIL

5 MIL

6 MIL

10 MIL

⇒ Note

There are many variables that affect the temperature and speed (paper, ink, toner, moisture). This sheet is just a
guide, but don't hesitate to try new combinations. Finally, remember that speed and temperature can vary with
the size of print; smaller prints require more speed, larger prints require less speed.

$OO 3UHVVXUH 6HQVLWLYH 0DWHULDOV

Most often, when pressure sensitive materials are run at 120 ºF, they tend to apply cleaner. That is to say, the
"sil v erin g" usua lly s een with thes e pr o d ucts becomes l ess ev i d ent or may ev en d i sa ppear.

/DPLQDWLRQ

Gloss
Lustre
Matte
Gloss
UV Gloss
Gloss 225-235 ºF

Gloss
UV Gloss

215-220 ºF

(102-104 ºC)

220-225 ºF

(104-107 ºC)

(107-113 ºC)

235-245 ºF

(113-118 ºC)

3-7 fpm/9-12 fpm

3-5 fpm/6-9 fpm

3-5 fpm/6-9 fpm

3-5 fpm/6-9 fpm

Most laminating on the ORCA-III is done with 80 ps i on the main lamina tor roll and 80 psi on both the pull roll
clutc h and the pull rolls. (This ma y vary with the thic knes s of the paper(s) used. The thick pap ers t raditionally need
a full 75-80 psi.

The thinner papers, such as t issu e p aper s or light bond papers, c an r un as low as 55 psi (main laminat or r oll
pressure).

0RXQWLQJ

Most of the mounting for the ORCA-III laminator is done between 20 and 50 psi. The only "ru le" is not t o crush
your substrat e or cr eate a n impression in your whit e s ilic one rolls with repea ted high pres sur e u se in the same place.

Again, slight heat (120 ºF) seems to help the adhesives flow when using the pressure sensitive materials.

9LQ\O 7UDQVIHU

The top roll heat should be set to 290 ºF, with as speed of 1.5-2.5 fpm. The main roll pressure should be at 90 psi.
The pu ll roll clutch should be at 50 psi. The pull roll should b e s et at 7 5-80 psi. Alwa ys allow t he t ransferred image
to cool prior to removing the t ra nsfer pap er.



GBC Pro-Tech 1997 October

3-37

Operation ORCA-III Operation Manual

Blank p age.

3-38



GBC Pro-Tech 1997 October

ORCA-III Operation Manual Maintenance and Troubleshooting

6HFWLRQ   0DLQWHQDQFH DQG

7URXEOHVKRRWLQJ

GBC Pro- Tech laminator s requ ire minimal
maintena nc e. However, regu lar maintena nc e is
essential to keep a ny piece of precision mac hinery at
peak p erformance. A maintena nc e s chedule and a
section of proc edures are included in this s ection.

Table 4-1: Maintenance Schedule

Daily

Monthly

• Clean the r o lls

• Ins pect th e el ectrical cord for

damage

• Inspect the footswitch cord for

damage

• Adjust the nip, i f needed

• Check the chain tens ion

• Ins pect th e area aroun d the

laminator for possible hazards (dust
buildup, combustible items stored
too clos e, etc.)

• Adjust the air cylinder rates, if

needed

To clean the laminator rolls:

WARNING

Exercise extreme caution while cleaning the

laminat or. Y ou ca n be c a ught i n the turning

rolls and crushed or burned.

1. While the laminator is at normal operating

temperature, put on the rubber gloves and, using
a rubber cement eraser, remove any heat
act i vated adhesive fr om t he rolls. Run the main
rolls in reverse and the pull rolls in f orward to
clean. Use the footswitch to rotate the rolls for
cleaning.

CAUTION

If r unning Scotchprint mat eria l, cle a n a l l the

release liner residue off the bottom roll

IMMEDIATELY. The residue hardens and

ruins the roll.

Every
Six
Months

• Lubricat e the grease f ittings a n d

chain

• Check wir e t erminat ion tightness

&OHDQLQJ

Tools required:

• Adhesive coa ted board

• 80% ( or stronger) isoprop yl alcohol ( or

dishwashing deter gent)

• Rubber cement eraser (optional)

• Several 100% cotton terry cloths

• Protective rubber gloves

CAUTION

Do NOT pick or pull heat activated adhesive

off the rolls when they are cold. You can cause

irreparable damage to the laminating rolls.

To clean beads of adhesive, dust and dirt from the
rolls:

1. Allow the laminator to cool slightly t o no higher

than 110 ºF (43 ºC).

2. Set the FWD/REV switch to the REV position.

3. Clea n the rolls using a moder ate amount of 80%

(or stronger) isopr opyl alc ohol on a cotton terry
cloth.



GBC Pro-Tech 1997 October

4-1

Maintenance and Troubleshooting ORCA-III Operation Manual

To clean the cabinet and covers:

CAUTION

Use the minimum amount of pressure

necessary to clean the rolls. You can destroy

the silicone layer on the rolls by pre s sing to

hard or scrubbing too long in one spot.

WARNING

Exercise care when cleaning the rolls with

80% (o r s tro nger) isopropy l alcohol:

•

Use only in a well ventilated area.

•

Wear rubber gloves.

•

Use only on cool rolls.

Cle aning heated r olls ca n igni te t he fumes .

CAUTION

Use only 80% (o r s tro nger) isopropy l alcohol

or a rubber cement eraser to clean the
laminating rolls. Harsh chemicals like toluene,
acetone or M EK des t r o y the silicone covering

of the rolls.

WARNING

Remove power from the laminator and make

sure it won’t be r eapplie d w hile yo u are

performing this procedure. You could be

severely shocked, electrocuted, or get your

fingers caught in the drive mechanisms.

Using a damp cotton t erry cloth (water only), c l ean
the exterior of the laminator.

WARNING

Do not use liquid or aerosol cleaners on the
laminator. Do not s pill liquid of any kind on
the laminator. You can be severely shocked,

electrocuted or cause a fire. Use only a damp

cloth for cleaning.

4. With the laminator rolls no hotter than 110 ºF

remove dust and dir t fr om t he s ilic one laminat ing
rolls by running an adhesive-coated boar d
through the laminator. Be sure to set the nip for
the thicknes s of the b oard used.

5. Allow the laminator to cool.

4-2



GBC Pro-Tech 1997 October

ORCA-III Operation Manual Maintenance and Troubleshooting

1

$GMXVWLQJ WKH 0DLQ 5ROO 1LS

The gap between the two main rolls is c alled the nip.
The pu rpos e of adjus ting the nip is to ensu re
continuous cont act between the laminating rolls as
the media is dr awn through t he mac hine. This
proc edu re must be done regular ly.

Tools required:

1

/8" hex wrench

1

/16" hex wrench

To adjust t he main roll nip:

CAUTION

The main rolls must be at room temperature

to achieve a proper nip setting.

7. Using t he

but ton head s c rews on t he adjus ting colla r on one

end of the lamina tor and line up the horizontal

and vertica l lines on the adjusting collar and the

shaft. Once they are aligned, tighten the button

head sc rews. Do this for the other side of the

laminator.

Written Zero

Figure 4-2: Written Zero Point and the

/16" hex wrenc h, loo sen t h e three

Point

0

5
10
15

Zero Point On the Shaft

Zero
Point On
the Shaft

1. Make sure that the machine has both power and

air. It is also necessary to ensure that the
up/down rates of the upper main roll are even
prior to setting the nip. If they are not, follow the
ra te adjusting p rocedure lat er in this section.

2. Rotate t he adjusting collar on eac h end of the

laminat or unt il it touc hes the lock collar.

Lock Collar
Button Head Screw

Adjusting Collar

30
25
20
15

Figure 4-1: Main Roll Nip Setting

3. Set the main roll pressure to 30 PSI on the front

contr ol panel.

4. Screw the adjusting collars down u ntil they sea t.

Shaft

Assembly

Written Zero

Point Lined

Up With the
Center Line
On the Shaft

Figure 4-3: Properly Aligned Shaft and

0

5
10
15

Adjusting Collar

8. The nip is now set.

Properly Set Nip

(Distance Between

Rolls is Equal)

Figure 4-4: Properly Set Nip

Bottom of the
Adjusting
Collar Lined
Up with the
Zero Point On
the Shaft

5. Ra ise the main roll.

6. Withou t moving the adju sting collars, draw a

zero on each collar scale.



GBC Pro-Tech 1997 October

4-3

Maintenance and Troubleshooting ORCA-III Operation Manual

$GMXVWLQJ WKH 3XOO 5ROO 1LS

CAUTION

The pull rolls must be at room temperature to

achieve a proper nip setting.

The gap between the two pull rolls is called t he nip.
The pu rpos e of adjus ting the nip is to ensu re
continuous cont act between the laminating rolls as
the media is dr awn through t he mac hine. This
proc edu re must be done regular ly.

Tools required:

1

/8" hex wrench

To adjust t he pull roll nip:

WARNING

Use extreme caution when servicing the

laminator with cabinet cover(s) open and

power applied. You could be severely shocked,

electrocuted, or get your fingers caught in the

drive mechanisms.

1. Open both ca binet cover s us ing the 5/32" hex

wrench b y removing the four sc rews holding each
cover in pl ace.

2. Make sure that the machine has both power and

air. It is also necessary to ensure that the
up/down rates of the upper pull roll are even
prior to setting the nip. If they are not, follow the
ra te adjusting p rocedure lat er in this section.

Adjusting Lock Collar

Nip Adjuster

Figure 4-5: Pull Roll Nip Setting Assembly

5. Set the pull roll pressure to 40 PSI on the back

contr ol panel.

7

6. Using t he

/64" hex wrench, loosen the lower lock

collar on each end of the laminat or.

7. Rotate eac h loc k collar to its f ully up p osition.

8. Lower the upper pull roll.

9. Rotate eac h loc k collar down u ntil it s eats. T his

is the zero p oint.

10. Raise the upper pull roll.

11. Without moving t he collars, tighten t he s et

screws.

12. The nip is now s et .

3. Raise the upper pull roll.

4. Set the nip adjuster on each end of the laminator

to zero. View the setting on the interior wall of
the lamina tor, not f rom inside the op en cabinet s.

4-4

Properly Set Nip

(Distance Between

Rolls is Equal)

Figure 4-6: Properly Set Nip



GBC Pro-Tech 1997 October

ORCA-III Operation Manual Maintenance and Troubleshooting

&KDLQ 7HQVLRQLQJ DQG 7DNH8S

Smaller chain adjustments on the ORCA-III
laminator are handled by the chain tens ioning
sprockets and the inner dr ive c hain take-up, however ,
when installing a new chain or when t he chain is
more seriously ou t of a djust ment, us e t he f ollowing
proc edu res t o adjust t he chain tens ion.

Tools required:

5

/32" hex wrench

•

1

• 1-

/8" wrench

• 13 mm wrench

To adjust the inner drive chain tension:

WARNING

Remove power from the laminator (the air

should remain connected) and make sure it

won’t be reapplied while you are performing

this procedure. You could be severely

shocked, electrocuted, or get your fingers

caught in the drive mechanisms.

1. Open t he drive side ca binet cover using 5/32" hex

wrench b y removing the four sc rews holding the
cover in pl ace.

2. Loosen the nut that secures the inner chain

tension a djuster sp rocket u sing the 1-

1

/8" wrench.

Inner

Outer

Chain

Outer

Chain

Tension

Check

Location

Outer

Chain

Tension

Adjuster

Sprocket

Figure 4-7: Location of the Inner and

Outer Chain Adjustments

Chain

Tension

Check

Location

Inner
Chain
Tension
Adjuster
Sprocket

Inner
Chain

Inner
Chain
Take Up

Motor
Sprocket

3. Move the adjuster sprocket unt il t here is

approximately ½" play measured at the inner
chain tension check location.

4. Tighten the nut that secures the inner chain

1

tension a djuster sp rocket u sing the 1-

/8" wrench.

5. Replace t he c abinet cover and r eapp l y power t o

the laminator.



GBC Pro-Tech 1997 October

4-5

Maintenance and Troubleshooting ORCA-III Operation Manual

To adjust the inner drive chain take-up:

WARNING

Remove power from the laminator (the air

should remain connected) and make sure it

won’t be reapplied while you are performing

this procedure. You could be severely

shocked, electrocuted, or get your fingers

caught in the drive mechanisms.

1. Open t he drive side ca binet cover using t he 5/32"

hex wrench by removing the four scr ews holding
the c o v er in place.

2. Loosen t he nut t hat secures the inner cha in take-

up using the 13 mm wrench.

3. Adjust the take up so that no slack is present at

any ti me. Do not over adjus t. The device is
intended to take up the slack cr eated by high and
low spot s on the sproc ket s. I t is not intended to
provide chain tensioning.

4. Tighten nut that secures the inner chain take-up

using the 13 mm wrench.

5. Replace t he c abinet cover and r eapp l y power t o

the laminator.

To adjust the outer drive chain tension:

WARNING

Remove power from the laminator (the air

should remain connected) and make sure it

won’t be reapplied while you are performing

this procedure. You could be severely

shocked, electrocuted, or get your fingers

caught in the drive mechanisms.

4. Tighten the nut that secures the outer chain

tension a djuster sp rocket u sing the 1-

5. Replace t he c abinet cover and r eapp l y power t o

the laminator.

1

/8" wrench.

$GMXVWLQJ WKH $LU &\OLQGHU 5DWH

If the t op main roll or top pull roll move up or down
unevenly, the air c ylinder flow controls need to be
adjusted.

To adjust the air cylinder rate for the main rolls:

WARNING

Use extreme caution when servicing the

laminator with cabinet cover(s) open and

power applied. You could be severely shocked,

electrocuted, or get your fingers caught in the

drive mechanisms.

1. Open both ca binet cover s us ing the 5/32" hex

wrench b y removing the four sc rews holding each
cover in pl ace.

2. Turn the control clockwise to s low the up /down

ra te and counter-clockwise to increase the
up/down rate. To correct for uneven motion,
when the roll is going up, adjus t the flow controls
at the top of the air cylinders. To adjust for
uneven l o wering , s et t he air p res sure on the
laminating roll regulator at 100 PSI (690 kPa)
and make t he necessary adjust ments to t he fl ow
controls on the b ottom of t he air c ylinders.

1. Open t he drive side ca binet cover using t he 5/32"

hex wrench by removing the four scr ews holding
the c o v er in place.

2. Tighten the nut that secures the outer chain

tension a djuster sp rocket u sing the 1-

3. Move the adjuster sprocket unt il t here is

approximately ¾" play measured at the outer
chain tension check location.

1

/8" wrench.

4-6



GBC Pro-Tech 1997 October

ORCA-III Operation Manual Maintenance and Troubleshooting

laminating roll regulator at 100 PSI (690 kPa)
and make t he necessary adjust ments to t he fl ow
controls on the b ottom of t he air c ylinders.

Adjustment for

Raising the

Main Roll

Adjustment for

Lowering the

Main Roll

T urn Clockwise
To Slow the
Up/Down Rate

Turn Counter­Clockwise To
Increase the
Up/Down Rate

Figure 4-8: Adjusting the Main Roll Air

Cylinder Rate

3. Ideally, the main roll shou ld move down at a

slow r ate and up at a faster rate.

4. Reapply p ower and lower and raise the roll. T he

roll should fall and r ise evenly. If not, r ep eat this
procedur e. Adjust un til the rates are even.

To adjust the air cylinder rate for the pull rolls:

Adjustment for

Raising the

Pull Roll

Adjustment for

Lowering the

Pull Roll

T urn Clockwise
To Slow the
Up/Down Rate

Turn Counter­Clockwise To
Increase the
Up/Down Rate

Figure 4-9: Adjusting the Pull Roll Air

Cylinder Rate

3. Ideally, the pu ll roll shou ld move down at a slow

rate and up at a faster rate.

WARNING

Use extreme caution when servicing the

laminator with cabinet cover(s) open and

power applied. You could be severely shocked,

electrocuted, or get your fingers caught in the

drive mechanisms.

5

1. Open both ca binet cover s us ing the

wrench b y removing the four sc rews holding each
cover in pl ace.

2. Turn the control

ra te and

counter-clockwise

clockwise

to sl ow the up /down

to increase the
up/down rate. To correct for uneven motion,
when the roll is going up, adjus t the flow controls
at the top of the air cylinders. To adjust for
uneven l o wering , s et t he air p res sure on the



GBC Pro-Tech 1997 October

/

32

" hex

4. Reapply p ower and lower and raise the roll. T he

roll should fall and r ise evenly. If not , rep eat t his
procedur e. Adjust un til the rates are even.

WARNING

Do not adjust or otherwise tamper with any

controls, setti ngs , t rim po ts, locknuts, e tc.,

other than for the procedures described in this

section. These devices are carefully pre-set at

the factory and the proper procedures require

specialized training and equipment.

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Maintenance and Troubleshooting ORCA-III Operation Manual

/XEULFDWLRQ

Tools required:

1

" hex wrench

/

•

8

High temper ature grease or lithiu m grease

•

Grease gun

•

To lubricate t he laminator:

WARNING

Do not lubricate t he laminator when it is hot .

You can be burned.

WARNING

Remove power from the laminator and make

sure it won’t be r eapplie d w hile yo u are

performing this procedure. You could be

severely shocked, electrocuted, or get your

fingers caught in the drive mechanisms.

&RQWDFWLQJ 7HFKQLFDO 6XSSRUW

For ma c hine par ts and technical ser vic e:

North America: 1-800-790-7787.
Europe: [phone]

or fax: [phone].

Please provide serial number when calling for
service.

For f ilm a nd app lic ation qu es tions:

North America: 1-800-236-8843.
Europe: [phone]

or fax: [phone].

1. Open the drive and control side cab i net c overs

5

using t he

" hex wrench b y removing the four

/

32

screws holding eac h c over in place.

2. Using the grease gu n, lub ricate eac h grease
fitting with one squir t of high temperature grea se.
Ther e is a fit ting on each of the main roll
bearings, pull r oll bear ings, and on all f ive idler s
on the control side of the machine.

3. Lub rica te the cha i n using a soft c l oth and
automotive oil.

4. Close the cabinet covers.

4-8

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GBC Pro-Tech 1997 October

ORCA-III Operation Manual Maintenance and Troubleshooting

6FKHPDWLF 'LDJUDP

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GBC Pro-Tech 1997 October

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GBC Pro-Tech 1997 October

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2XWSXW 7URXEOHVKRRWLQJ *XLGH

Problem:

D waves in the image, not in the
laminate.

Hints:

• Check paper tension.

• Check relative moisture content
of the paper.

Problem:

Waves on only one side of the
output.

Hints:

• Check nip settings.

• Check for even paper tension.

Problem:

D waves in the laminate.

Hints:

• Increase clutch tension.

• Check roll pressures.

• Check nip settings.

Problem:

Angled waves on the output.

Hints:

• Check for insufficient clutch
tension.

• Check for insufficient main roll
pressure

Problem:

Straight waves in the output.

Hints:

• Decrease clutch tension.

• Check operational settings for
materials being used.

Other Common

Feed

Direction

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 noise from the
drive side of the laminator.



GBC Pro-Tech 1997 October

Hints:

• Increase chain tension,
decrease unwind brake
tension.

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GBC Pro-Tech 1997 October

ORCA-III Operation Manual Technical Information

6HFWLRQ   :DUUDQW\

/LPLWHG :DUUDQW\

GBC Pro-Tech Engineering C ompany, I nc . wa rr ants
the equip ment s o l d i s free from defects in mat erial
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 GBC Pro- Tech and
cannot be modified or amended.

GBC Pro - Tech’s sole and exclusiv e liabilit y 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 Pro-Tech’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,
flood, or other hazard.

([FOXVLRQV WR WKH :DUUDQW\

This warranty specifically does not cover:

1. Dama ge to the lamina ting r olls c aus ed b y knives ,

ra z or blades, other shar p objects , or f ailure
cau sed by a dhes i ves .

2. Dama ge to the machine caused b y lif ting, tilting,

and/ or any attempt to posi tion the mac hine other
than rolling on the installed cast ers on even
surfaces.

3. Improper use o f the mach i n e.

This warra nty sp ecif ic ally does not c over dama ge to
the laminating r ollers caused b y knives, r azor blades,
other sharp ob jects, failu re ca used by adhesives or
improper use of the machine. Warra nty rep air or
replacement does not extend t he warra nty beyond t he
initial one yea r period fr om the date of delivery.

CAUTION

Unauthorized custo mer alte rat ions will void

this warranty.

THE WARRANTY MADE HEREIN IS IN LIEU
OF ALL OTHER WARRANTIES, EXP R ES S OR
IMPLIED, INCL UDING 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 PR OF IT OR OTHER INC IDENTAL OR
CONSEQUENTIAL DAMAGES ARISING OUT
OF THE USE OR INAB I LITY T O USE THE
EQUIPMENT.



GBC Pro-Tech 1997 October

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6HFWLRQ   7HFKQLFDO ,QIRUPDWLRQ

6SHFLILFDWLRQV

Table 6-1. ORCA-III Laminator Specifications

Characteristic Specifications

Dimensions
(L x D x H)

Weight Uncrated: 2500 lbs (1179 kg)
Laminating Rolls 61" (155 cm) roll face with

Laminating Opening 1.5" (3.8 cm) maximum opening

Laminating Material Uses heat activated and

Laminating Speeds 0 to 14.5 fmp (0 to 4.5 mpm)
Post Lamination Fanless cooling system provides

82" x 33" x 60"
(2.1 x .84 x 1.52 m)

thermally conductive high
release silicone surface; upper
and lower main rolls internally
heated; temperature controlled
by state-of-the-art infrared
sensors and digital PID
controllers

controlled with dual air
cylinders.

pressure-sensitive materials 0 ­55" (0 - 140 cm) wide on a 3"
(7.6 cm) ID core

uniform, filtered air for thermal
shock without exposure to
dangerous fan blades.

Vinyl Transfer Complete roll to roll transfer,

lamination, and edge trimming
in one pass

Safety Features

Installation
Requirement



GBC Pro-Tech 1997 October

• Two emitter-receiver

phot oel ectri c s ystem s
protect rolls from damage.

• Emergen cy kick cables front

and rear.

• All electrical and moving

mechanical parts are
located in bolted cabinets

• Four em ergency stop

buttons

220 to 240 VAC, 50/60 Hz, 55
A. Or, in Europe only, 3-N
phase, 32 A per phase.

Air: 2 cfm at 100 psi, min im um

3

at 700 vPa)

(0.5 m

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