GBC Orca 1600 Operation And Maintenance Manual

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ORCA 1600 OPERATION &

MAINTENANCE MANUAL

Do not duplicate without written permission.

ORCA 1600

GBC

ech

- T

GBC Pro - T ech

4151 Anderson Road

DeForest, WI 53532 Revision : A Ph: ( 608 ) 246 - 8844 Part number : 930 - 061

Fx: ( 608 ) 246 - 8645

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Read me fileOrca 1600 Operation and Maintenance Manual

Read Me File . . . . . . . . .

The information in this publication is provided for reference and is believed to be accurate and complete. GBC Films Group 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 Films Group 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 Films Group or others. GBC Films Group assumes no liability arising from infringements of patents or any other rights of third parties.

This publication is copyrighted © 2000 by GBC Films Group. All rights reserved. The information contained in this publication 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 Films Group.

The following information will explain how to move around within the electronic version of this publication. The hand will change to a pointer finger identifying hyperlinked areas. When

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Should you find an error within this publication or would like to make a suggestion, please utilize the fax correspondence sheet following this read me file and fax it to the number provided. Your comments and help will ensure up to date information. Thank you.

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Fax Correspondence

Fax number : ( 608 ) 246 - 8645 Date :

To : Sean Flood at GBC Pro-Tech

4151 Anderson Road

DeForest, WI 53532

From :

Company :

Address :

Phone number : ( ) Fax number : ( )

Read me fileOrca 1600 Operation and Maintenance Manual

Re : Orca 1600 Operations and Maintenance Manual ( 930061 )

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Correction (s):

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Section 1.0 Safety

1.1 Symbols ......................................................................................................1 - 1

1.2 Pneumatic safety ........................................................................................1 - 2

1.3 Safety features ............................................................................................1 - 2

1.4 Mechanical safety ......................................................................................1 - 4

T able of ContentsOrca 1600 Operation and Maintenance Manual

Table of Contents

1.5 Heating safety .............................................................................................1 - 4

1.6 Maintenance safety ....................................................................................1 - 5

1.7 Installation ..................................................................................................1 - 5

1.8 Operation ...................................................................................................1 - 8

1.9 Applications ...............................................................................................1 - 10

1.10 Troubleshooting .......................................................................................1 - 12

1.11 Maintenance ............................................................................................1 - 12

1.12 Label Explanation ....................................................................................1 - 14

Figure 1.12.1 Label Location ....................................................1 - 16

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Section 2.0 Warranty

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

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

Section 3.0 Specifications

3.1 General .......................................................................................................3 -1

3.2 Consumables................................................................................................3 - 2

3.3 Function ......................................................................................................3 - 3

3.4 Electrical ....................................................................................................3 - 4

3.5 Dimensions .................................................................................................3 - 5

Section 4.0 Installation

4.1 Pre-installation check list ..........................................................................4 - 1

Figure 4.1.1 Suggested floor layout ..............................................4 - 3

4.2 Know your machine ...................................................................................4 - 4

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4.3 Unpacking ..................................................................................................4 - 5

4.4 Shrink wrap ..............................................................................................4 - 5

4.5 Crated .........................................................................................................4 - 6

4.6 Accessory pack ..........................................................................................4 - 9

4.7 Electrical connection ..................................................................................4 - 9

4.8 Air connection ............................................................................................4 - 11

4.9 Installing levelers .......................................................................................4 - 12

4.10 Leveling ...................................................................................................4 - 13

4.11 Calibrations .............................................................................................4 - 14

Section 5.0 Operations

5.1 Power ON/ OFF .........................................................................................5 - 1

5.2 Front control panel ....................................................................................5 - 2

Figure 5.2.1 Front control panel ............................................................5 - 4

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5.3 Rear control panel ......................................................................................5 - 5

Figure 5.3.1 Rear control panel ............................................................5 - 7

5.4 Setting temperature ....................................................................................5 - 8

5.5 In case of an emergency .............................................................................5 - 9

5.6 Film loading/ unloading ...........................................................................5 - 10

5.7 Main roller nip ..........................................................................................5 - 11

5.8 Pull roller nip ............................................................................................5 - 12

5.9 Shutdown procedure ..................................................................................5 - 12

Section 6.0 Applications

6.1 Temperature chart .....................................................................................6 - 1

6.2 Helpful hints ...............................................................................................6 - 2

6.3 Temp conversion chart ...............................................................................6 - 3

Figure 6.3.1 Temperature conversion chart .................................6 - 4

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6.4 Charts and diagrams .................................................................................6 - 5

Chart - 0 ( blank chart ) ..........................................................................6 - 6

Diagram - 0 .............................................................................................6 - 7

Chart - 1 ( 1 pass mounting ) ...................................................................6 - 8

Diagram - 1 .............................................................................................6 - 9

Chart - 2 ( PSA decaling ) .....................................................................6 - 10

Diagram - 2 ............................................................................................6 - 11

Chart - 3 (Mounting a PSA decal ) ........................................................6 - 12

Diagram - 3 ............................................................................................6 - 13

Chart - 4 ( Thermal decal ) ...................................................................6 - 14

Diagram - 4 ............................................................................................6 - 15

Chart - 5 ( Mounting a thermal decal ) .................................................6 - 16

Diagram - 5 ............................................................................................6 - 17

Chart - 6 ( Thermal encapsulation ) ......................................................6 - 18

Diagram - 6 ............................................................................................6 - 19

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Section 7.0 Troubleshooting

7.1 Wave problems ..........................................................................................7 - 1

7.2 Film problems .............................................................................................7 - 3

7.3 Machine problems .....................................................................................7 - 4

7.4 Glossary ......................................................................................................7 - 5

Section 8.0 Maintenance

8.1 Maintenance schedule ...............................................................................8 - 1

8.2 Cleaning the rollers ..................................................................................8 - 2

8.3 Dust - Pre-coated boards ............................................................................8 - 3

8.4 Dirt and PSA adhesive - Alcohol and cloth ...............................................8 - 3

8.5 Thermal adhesive .......................................................................................8 - 4

8.6 Clean the laminator ....................................................................................8 - 5

8.7 Clean the control panels .............................................................................8 - 6

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1.0 Safety

CAUTION

Do not attempt to operate your O RC A 1600

laminator until you have read this

section carefully!

SafetyOrca 1600 Operation and Maintenance Manual

CAUTION

Indicates a potentially hazardous situation

which, if not avoided, could result in minor

or moderate injury, or alerts against unsafe

practices or alerts against actions which

could damage the product.

Your safety, as well as the safety of others, is important to GBC Films Group. This section contains important safety information.

The following symbols are used throughout this manual to indicate Information, Caution,

Warning, Danger and Electrical Shock conditions.

1.1 Symbols

WARNING

Indicates a po tentially hazardou s situation

which, if not avoided, could result

in se rio u s in ju ry .

DANGER

Indicates an imminently hazardous situation

which, if not avoided, could result in death

or serious injury.

INFORMATION

Indicates helpful information that should be

considered before, during, or after an

action, step or procedure is given.

ELECTRICAL

SHOCK

Indicates an electrical shock situation which,

if not avoided, could result in serious

paralyzation of the body or death.

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Safety Orca 1600 Operation and Maintenance Manual

1.2 Pneumatic safety

The Orca 1600 laminator has been designed with safety as a primary consideration; however, you must become thoroughly familiar with the controls, proper operation, proper service procedures and safety features of the laminator before using or servicing the unit.

The pneumatic system used to provide downward pressure on the top main roller and the top pull roller is capable of producing great amount of forces. This force is applied to any object presented in the opening (called the nip) between the two rollers.

CAUTIO N

1.3 Safety features

Important safety features of the Orca 1600

laminator are the emergency stop push buttons ( E- STOP ), the emergency stop cables ( E-CABLE ) and the photo electric sensors ( PHOTO-EYE ). It is recommended that you become thoroughly familiar with each of these safety features purpose and how to use them in the event of an emergency.

E- STOP

T o engage any one of the four E-STOPs, press

the push button down. Any one of these, when engaged, removes power to the motor and opens the main roller and pull roller nips.

Objects other than m edia, film or app roved

substrates, will cause irreparable damage

to the rollers if caugh t in the n ip.

Use care in lowering the top main and/ or pull rollers. Know how to react quickly in an emergency. The top main laminator roller UP-DOWN switch is located on the front control panel. The top pull roller UP-DOWN switch is located on the rear control panel. This switch controls the up and down motion of the top pull roller .

Before pressing either of these switches to the DOWN position, ensure that nothing is in the nip areas. If any problem or danger should occur, depressing any of the emergency stop push buttons or engaging the emergency cables, described in Section 1.3, stops the rollers from closing and raises them completely.

Engaged

Push

Turn

Disengaged

To continue operation, all E-STOPS must be

in the up position. To reset the E-STOP, twist the button 1/4 turn counter clockwise and reset the main roller UP-DOWN switch to UP.

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SafetyOrca 1600 Operation and Maintenance Manual

E- CABLE

To engage the front or rear E-CABLE, push

in on the cable using your foot. Either cable, when engaged, removes power to the motor and opens the main roller and pull roller nips. The E-CABLE are provided in the event you are unable to reach one of the four E-STOPs.

PHOTO-EYE

The Orca 1600 is equipped with three sets of

PHOTO-EYEs, one at the main roller nip, one behind the pull roller nip and one in front of the pull roller nip. The PHOTO-EYEs, when blocked by an object, stop the rollers from turning and will resume turning when the sensor is no longer blocked.

This safety feature not only protects the

operator but also protects objects from entering the rollers nip causing damage. The PHOTO-EYEs are calibrated at time of installation.

With the FWD/ REV switch in the FWD

position, the PHOTO-EYE at the front of the main roller nip (1) and the rear of the pull roller nip (3) are engaged.

Press in or down

GBC

To continue operation, reset the main roller

UP-DOWN switch to UP and continue on with operation. The E-CABLE automatically resets itself when the cable springs back to it’s original position. All E-STOPs must be in the unlatched position as well.

The E-CABLE may be adjusted if you feel

the cable is too sensitive or too loose. Contact your local service representative for this adjustment.

( 2 ) Fr o n t p u ll r o lle r

photo-eye

( 3 ) Re a r p u ll roller ph o to -e ye

( 1 ) Main ro ll e r

photo-eye

With the FWD/ REV switch in the REV position, the PHOTO-EYE at the front of the pull roller nip (2) is engaged only .

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Safety Orca 1600 Operation and Maintenance Manual

1.4 Mechanical safety

WARNING

Never remove or open any guarding or

covers from th e m a chin e. Th ese a re placed for you protection as well as

the protection o f the m a ch ine.

WARNING

Never place hands, fingers or objects

through any opening of the side fram e. Your

hand or fingers may be pinched or crushed

or you m ay cau se d am g e to the machine.

1.5 Heating safety

The heating components of the Orca 1600 can

reach temperatures of over 200 oF ( 100 oC ).

DANGER

At these temperatures there is a danger of severe burn if the rolls are touched during

setup, operation or servicing.

In the event of a run away heat failure, the machine is equipped with a thermal cut off switch. This switch will remove power to the heating system before any damage can be caused by the run away heat failure.

WARNING

W hen sw inging out or in an unw ind,

keep hands and fingers away from

the pivot end. Your hand or

fingers may be pinched.

WARNING

Keep hands and fingers away from the

ends of the removable idlers when

rem oving o r installin g th em at

various loca tions on th e m ach ine.

IN FORMATION

If run aw a y h ea t failure occu rs, call

your loca l service represen tative

before using the m achine again.

CAUTIO N

Neve r leave th e roller in the do w n p osition

w ith o u t r ollin g wh e n th e ro ller s a r e h e a ted .

This w ill ca u s e d a mage to th e r o ller s.

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SafetyOrca 1600 Operation and Maintenance Manual

1.6 Maintenance safety

Any maintenance requiring the cabinets to be opened with electrical power connected should be only performed by a qualified service technician.

INFORMATION

Only a qualified service technician should

perform any procedure requiring the

cabinet doors to be opened.

1.7 Installation

The following symbols are positioned at

various points in Section 4 Installation.

CAUTION

Failure to follow the pre-installation check

list can result in damage to the laminator.

The word qualified is defined as;

Qualified ;

• Any engineer that has experience with electrical and mechanical design of lamination equipment. The engineers should be fully aware of all aspects of safety with regards to lamination equipment.

• Any commissioning or service engineer must be of competent nature, trained and qualified to GBC Films Group standards to fulfill that job. This person will have completed and passed the full service training course from GBC Films Group.

WARNING

The operating environment must be free of

dust, flammable liquids and vapors. You can

be injured by inhaling chemical vapors.

WARNING

Vapor build up or stored flammable liquids can cause a fire. Excessive dust can damage

the laminator.

• Any GBC T echnician, GBC Specialist, and / or GBC Films Group T echnician that has been through the GBC Pro-Tech service training course.

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 output quality.

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Safety Orca 1600 Operation and Maintenance Manual

WARNING

The Orca 1600 Laminator is a large and

heavy piece of equipment. It is necessary to

employ LICENSED R IGGERS ONLY to move the lam inator. The lam inator is not

de sig n e d to b e tip ped u p or sidew a y s in a n y

way. Such action disturbs the exact alignment of the rolling parts of the machine and requ ires extensive realignm en t. You can

be crushed or seriously injured.

INFORMATION

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.

INFORMATION

Depending on the destination and customer

preference, your machine may be shipped in

various ways. The laminator may arrive

shrink wrapped or in a plywood crate on a

skid. Please follow the unpacking procedure

that pertains to your method of shipment.

CAUTION

Do not use a knife or other sharp object to

remove the shrink wrap from around the

laminator. You can cause irreparable

damage to the rollers.

INFORMATION

Before signing the Bill of Lading, you

Do not attempt to move the laminator across

without trained and qualified riggers. You

should be sure to inspect the crate

and / or pallet for signs of damage or

missing items; if applicable, make

note of this on the Bill of Lading.

WARNING

The unpacking process requires at least two

people. You can be severely injured, crushed

or cause damage to the laminator.

WARNING

anything other than a flat level surface

can be crushed or seriously injured.

INFORMATION

GBC Film Group's warranty does not

cover malfunction of the equipment due to

mishandling and / or tipping. GBC Films

Group bears no responsibility for personal

injury or damage due to moving the

laminator improperly.

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SafetyOrca 1600 Operation and Maintenance Manual

CAUTION

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

can damage the laminator.

INFORMATION

Do not put packing screws on the floor.

They can cause problems when trying to roll

the laminator into position or you can

become injured if stepped on.

INFORMATION

About recycling: The crate components can

be reused for shipping the laminator again

or can be disassembled and the wood and

screws recycled. The shrink wrap is not

recyclable, so it must be discarded.

INFORMATION

En su re sufficien t space f or op en ing of the

cabinets for maintenance and servicing.

CAUTION

A second person must support the side labeled 5 in Figure 4.5.1 It can fall and

damage the laminator or cause harm to you

and others.

WARNING

Do not attempt to use the ramps if they are

not secured to the pallet. Ensure the pallet is

on a flat even surface before attempting to

roll the machine off.

ELECTRICAL

SHOCK

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.

ELECTRICAL

SHOCK

On ly a qu alified electrician sho u ld verify

the voltage. Yo u can b e severely sh ock ed ,

electrocuted or ca use a f ire.

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Safety Orca 1600 Operation and Maintenance Manual

1.8 Operation

WARNING

Do n o t opera te the m a ch ine w ith th e

control side or drive side cabinet

in th e o p en p o s itio n .

various points in Section 5 Operation.

The following symbols are positioned at

WARNING

ELECTRICAL

SHOCK

Do not op er a te th e la m inator if th e p ower

cord is damaged or frayed. You can be

severely shock ed , electrocuted o r cau se a

fire. Contact a qu alified electrician to

replace the cor d.

IN F OR MATIO N

Th e u pp er m a in roller an d the u p per p u ll

rolle r s h o u ld b e in th e ra is ed p o s itio n .

Do not wear ties, loose fit clothing or

dangling jewelry while operating or

servicing the laminator. These items can get

caught in the nip and choke you or you can

be crushed or burned.

WARNING

W h en the lam in ator rollers are in

motion, keep hands and fingers

away from the nip of the rollers.

You may be CRUSHED or BURNED!

ELECTRICAL

SHOCK

Th ese calibration s req uire th e lam ina tor

to be po w ered u p w h ile the cabin ets

are open ed .

Page 1 - 8

IN FO RMAT ION

Th e la minato r will only turn o n if

all E-ST OPs are un latched .

IN FO RMAT ION

Th e cen ter pos ition is to preven t jam ming

of the m otor when ch an gin g d irections

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SafetyOrca 1600 Operation and Maintenance Manual

IN FO RMAT ION

Top tem p eratu re con trol un it on/ o ff

switch must b e o n to t u r n t h e lo wer

temp erature co n trol unit to on .

IN FO RMAT ION

W h en d ecreasin g p ressu re, allow the

pressure g u age to dro p b elow the desired

value, then in crease p ressu re to th e set

pressure d esired . Th is allow s fo r a more

accura te pressu re read ing .

IN FORMATION

When requiring top and bottom heat, it is recom m en d ed to set both tem p eratu res to

the s a me set point.

INFORMATION

Th e m a xim u m set p oint tem p eratu re

is 270

F ( 132 oC ).

IN FO RMAT ION

W hen an emergency stop feature is activated

an d th e main r o ll is in the up p o si tio n , th e

pu ll r o ll will on ly s ta y in the u p positio n

until the em ergen cy stop fea ture is

deactivated.

IN FORMATION

INFORMATION

Th e minim u m set p o in t te m p e ra tu r e

is 32

F ( 0 oC ).

IN FO RMAT ION

W hen a safety feature is engaged, the

upper rollers raise and power to

the drive m o tor is rem ov ed.

Th e m o tor m u st be en ga ged fo r the co oling

fans to t u r n o n. If th e fa n sw it ch is in th e

"o n " p o s ition, the fa n s will au to matica lly

turn on wh en the motor is engaged.

IN FO RMAT ION

Th e u pp er m a in ro ller UP / DOW N switch

resets the ma in ro ller to the correct po sition.

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Safety Orca 1600 Operation and Maintenance Manual

1.9 Applications

CAUTIO N

Do n o t use an o pen b lade to cu t

the w eb nea r th e rollers.

You ca n p u t cuts into th e rollers!

INFORMATION

The nip can only be changed with the

upper roller in the up position.

IN FO RMAT ION

This w ill p re v ent the p u ll r o llers f ro m

contacting if the a ir shou ld be removed.

The following symbols are positioned at

various points in Section 6 Applications.

WARNING

Do not wear ties, loose fit clothing or

dangling jewelry while operating or

servicing the laminator. These items can get

caught in the nip and choke you or you can

be crushed or burned.

IN FO RMAT ION

For o p timal tempera tu r e s ettin g s o f

various laminates, contact your supp lier or sales rep resen tative.

Page 1 - 10

IN FO RMAT ION

Gen eral ru le: Sm aller prin ts requ ire m ore

speed or less tem pera ture. L arg er p rints

require less sp eed o r m o re tem per ature.

IN FO RMAT ION

Use film brake tension to control the

separa tion po int of the r elease liner.

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SafetyOrca 1600 Operation and Maintenance Manual

INFORMATION

Sp e ed s a n d temper a tu re s will affe c t th e

bond strength of thermal adhesives.

IN F OR MA T ION

Not all papers and inks are compatible with

ther mal film s . T e st th e co mbin a tio n s f irst.

IN F OR MATIO N

CAUTIO N

Excess pressure can damage the laminating

rollers. Alway s u se the m in imu m roll

pressure n ecessa ry to co m p lete the task.

IN FO RMAT ION

Never stop the lam inator when an image is

within the n ip of either set of ro llers.

Th e m o un t ad h esive m u st no t exceed 1 in.

the w idth of the substrate. If it does, you

w ill e xp e rie n ce c omplications with th is

application.

INFORMATION

Ex c es siv e pressu r e will cause the

substrate to bow or flatten.

IN FORMATION

IN FO RMAT ION

Lam inates and papers should always be

stored in a co n trolled en virom en t.

Excessive brake tension may cause the

imag e to curl. A lw ays u se the minimum

amoun t of brake for the job.

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Safety Orca 1600 Operation and Maintenance Manual

1.10 Troubleshooting

The following symbols are positioned at

various points in Section 7 Troubleshooting.

WARNING

Do not wear ties, loose fitting clothing or

dangling jewelry while operating or

servicing the laminator. These items can get

caught in the nip and choke you or you can

be crushed or burned.

1.11 Maintenance

The following symbols are positioned at

various points in Section 8 Maintenance.

WARNING

Do not wear ties, loose fit clothing or

dangling jewelry while operating or

servicing the laminator. These items can get

caught in the nip and choke you or you can

be crushed or burned.

INFORMATION

For optimal temperature settings of

various laminates, contact your

supplier or sales representative.

WARNING

Do not wear ties, loose fitting clothing or

dangling jewelry while operating or

servicing the laminator. These items can get

caught in the nip and choke you or you can

be crushed or burned.

INFORMATION

Improper maintenance, can

result in poor output quality.

ELECTRICAL

SHOCK

Remove power from the laminator before

servicing. You can be severely shocked,

electrocuted or cause a fire.

INFORMATION

Below is a recommended maintenance

schedule. Before performing any of the steps

listed, read through the procedures first.

Please follow the instructions pertaining to

the step you are performing.

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SafetyOrca 1600 Operation and Maintenance Manual

CAUTIO N

Use o nly isop rop yl alcoh ol or ru b b er cem en t

eraser to clean th e rollers. Ha rsh chemicals

like toluene, aceton e, or MEK can d estroy

the silicone covering of th e rolls.

CAUTIO N

Exer cise care w h en cleanin g the la m inating

rolle rs with 80 % is op r o p y l a lco h o l:



Us e o nly in a well ve n tila ted area

W ear rubber gloves

Use o nly on co ol rolls

CAUTIO N

CLEANING HEATED ROLLERS CAN

IGNITE THE FUMES!

CAUTIO N

Do NO T pick or pull heat activated adhesive

off the rolls w h en th ey a re cold. Y o u ca n

cause irrepa rab le da m ag e to the

lam inating r ol ls.

CAUTIO N

Ex c es siv e pressu r e c an des tro y th e silico n e

layer by pressing to hard or scrubbing

too long in one spot.

IN FO RMAT ION

Keep the terry cloth tow el k ind of d am p to

mak e th e rub b ing of the roller sm ooth .

ELECTRICAL

SHOCK

Do not use liquid or aerosol cleaners on the

laminator. Do not spill liquid of any kind on

the laminator. You can be severely shocked,

electrocuted or cause a fire. Use only a damp

cloth for cleaning unless other wise

specified.

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Safety Orca 1600 Operation and Maintenance Manual

1.12 Label locations

WARNING

ACHTUNG

Posted at various locations on the Orca 1600

Laminator are important safety labels. Pay careful attention to these labels at all times! Figure 1.12.1 illustrates the location of each of these labels.

DANGER

GEFAHR

HAZARDOUS VOLTAGE

To be serviced only by trained and authorized personnel.

Lockout power b efore servicing

Moving Parts: Keep hands and fingers away . You may be crushed and/ or cut.

M ISE EN GARDE

Moving parts can crush and cut.

Hazardous Voltage: Do not open these cabinets. This machine is to be serviced only by trained and authorized personnel.

WARNING

ACHTUNG

MISE EN GARDE

Crush and burn haza rd. S tay clear of moving rollers. Stop m achine and raise roll befo re cleaning.

WARNING

ACHTUNG

M ISE EN GARDE

Carefully read Operator's Manual before handling this machine. Observe instructions and safety rules when operating.

Roller Pinch Point: Keep hands and fingers away . You may be crushed and/ or burned.

Page 1 - 14

Read Manual: Read and understand the Operations Manual before attempting to run this machine.

Page 26

SAFETY INSTRUCTIONS

SICHERHEITSRICHTLINIEN

CONSIGNES DE SECURITE

1. Read and un derstan d the O peration M a n ualand a ll s a fety lab e ls before ope r a ting thi s m achin e .

2. Only a trained person is to be per m itted to o p erate th is mac h ine. Tr a in in g sho u ld includ e in struct io n in operation under normal conditions and emergency situations.

3. This machine is to be serv iced on ly by trained and authorized personnel. Follo w lock o u t proc e d ures b e f o r e servicing.

4. Never reach into the m ach ine for any reason unless the m a ch ine is at a CO M PLE TE S T OP.

5. Never leave the m ach ine stop ped in such a m ann er that an other w o rker can start the machine while you are working on o r within th e m achin e .

6. Never change or defeat the function of elec tr ic al interlo c k s or oth e r m achin e " sh utdow n " switc h es.

7. Before starting this machine, check that:

- All persons are clear of the machine.

- No m ainten a nce wo rk is be in g perfo r m ed on t h e mac h i n e .

-All g u ards ar e in place .

-All parent rolls are well chucked in the unwind stands.

- The ma ch ine is free of paper scra ps , wra p s and ja ms.

8. There is potential hazard of entaglemen t in th is m achin e caus e d by item s such as long hair, loo se clot h i n g , and jew elry. Make sure your clothing and hair fit clos e ly to yo u r body and th a t a ll je w elry, rings and watches are removed.

SafetyOrca 1600 Operation and Maintenance Manual

Lift Here: This point may be used as a lifting point.

If ignored, damage will occur to the laminator.

Refer to Figure 1.12.1 illustrates the location of each of these labels.

Safety Instructions: Read this label first before all

else!

Electrical Shock: Live voltage present. Exercise extreme caution. You may be electrocuted!

Page 1 - 15

Page 27

Safety Orca 1600 Operation and Maintenance Manual

g p

Figure 1.12.1 Label placement

WARNING

ACHTUNG

MISE EN GARDE

Crush and burn hazard. Stay clear of mo ving rolle r s. Stop machine and raise roll before cleaning.

( Back of cabinet )

( x 2 in re ar )

WARNING

ACHTUNG

MISE EN GARDE

Moving parts can crush and cu t.

( Left side frame )

! ! !

WARNING ACHTUNG

MISE EN GARDE

DANGER

GEFAHR

HAZARDOUS VOLTAGE

To be serviced only by trained and authorized personnel.

Lockout power before servicing

( Front of cabinet

WARNING

ACHTUNG

MISE EN GARDE

Crush and burn hazard. Stay clear of mo ving rolle r s. Stop machine and raise roll before cleaning.

( Right sid e frame )

( Front of cabinet )

( x 2 in front )

WARNING

ACHTUNG

MISE EN GARDE

Crush and burn hazard. Stay clear of mo ving rolle r s. Stop machine and raise roll before cleaning.

( Left side frame )

( Front of cabinet )

Crush and burn hazard. Stay clear of mo ving rolle r s. Stop machine and raise roll before cleaning.

( Ba c k o f c abinet )

Pro - Tech

SAFETY INSTRUCTIONS SICHERHEITSRICHTLINIEN CONSIGNES DE SECURITE

1. Read and understand the Operation Manualan d a ll safe t

labels before

erating this machine.

2. Only a trained person is to be ermitte d to operate this machine .

Trainin

should include instruction

in o

eration under normal conditions

and emer

ency situations.

3. This machine is to be servic e d o nl

by trained and authorized personnel.

rocedures before

Follow lockout servicin

4. Never reach into the machine for an

reason unless the machine is at a COMPLETE STO P .

5. Never leave the machine sto

ed in

such a manner that another worker can

ou are workin

start the machine w hile on or within the m achine.

e or defeat the function of

6. Never chan

electrical interlock s or othe r m a chin e " shutdown " switches.

this machine, check that:

7. Before startin

- All

ersons are clear of the machine.

erformed

- No maintena nce w ork is bein

on the ma chine .

-All

uards are in place. arent rolls are w e ll ch ucke d in the

-All

unwind stands.

- The machin e is free of paper scraps,

wra

s and jams.

8. There is potential hazard of entaglement

in this machine ca used b

item s such as

hair, loose clothing, and jewelry.

lon Make sure

our clothing and hair fit

to your body and that all jewelry,

closel

s and watches are removed.

rin

WARNING

ACHTUNG

MISE EN GARDE

Carefully read Operator's Manual before handlin this machine. Observe instructions and safet rules when operating.

( Ba c k o f c abinet )

Front of cabinet

Page 1 - 16

Page 28

2.0 Warranty

GBC Films Group warrants the equipment sold

is free from defects in material and workmanship for a period of one ( 1 ) year parts and 90 days labor from the date of installation. This warranty is the only warranty made by GBC Films Group and con not be modified or amended.

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

WarrantyOrca 1600 Operation and Maintenance Manual

CAUTION

Unauthorized customer alterations will

void this warranty.

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

2.1 Limited Warranty

This warranty specifically does not cover damage to the laminating rollers caused by knives, razor blades, other sharp objects, failure caused by adhesives or improper use of the machine. Warranty repair or replacement does not extend the warranty beyond the initial one year period from the date of delivery .

2.2 Exclusions to the Warranty

This warranty specifically does not cover;

1. Damage to the laminating rollers caused by knives,

razor blades, other sharp objects or failure caused by adhesives.

Page 2 - 1

Page 29

Warranty Orca 1600 Operation and Maintenance Manual

2. Damage to the machine caused by lifting, tilting and/

or any attempt to position the machine other than rolling on the installed castors on even surfaces.

3. Improper use of the machine.

4. Damage due from unqualified person(s) servicing the

machine.

Qualified

• Any engineer that has experience with electrical and mechanical design of lamination equipment.The engineers should be fully aware of all aspects of safety with regards to lamination equipment.

• Any commissioning or service engineer must be of competent nature, trained and qualified to GBC ProT ech standards to fulfill that job. This person will have completed and passed the full service training course from GBC Pro-T ech.

• Any GBC T echnician, GBC Specialist, and / or GBC Pro-T ech Technician that has been through the GBC Pro-T ech service training course.

Page 2 - 2

Page 30

3.0 Specifications

Specifications provide all of the technical data for

the Orca 1600 Laminator .

3.1 General

SpecificationsOrca 1600 Operation and Maintenance Manual

Description:

Features:

• Mid level, wide format color finisher for the sheet fed ink jet market. The Orca 1600 is a self standing, bi-directional laminator ..

• T wo swing out film unwinds ( 1 upper, 1 lower )

• One swing out print unwind

• T wo rewinds ( 1 upper front, 1 lower rear center )

• Infeed and oufeed tables

• Pressure plate

• Footswitch

• Bi-directional operations

• Four emergency stop push buttons ( E-STOPs )

• Front and rear emergency cables ( E-CABLEs )

• Photo-electric nip sensors

• Independent top and bottom heater units

• T wo fixed web tension idlers ( 1 lower, 1 upper )

• Three repositionable web idlers

• No slip core grip chucks ( 2 per unwind )

• Speed ranges from 0 to 15 ft/min ( 0 - 4.6 m/min )

• Pneumatic air cylinders for roller nip control

• T wo removable cooling ducts ( 1 upper, 1 lower )

• Multiple thermal protection circuitry

Applications:

• Single sided lamination

• Encapsulation

• Mounting

• Decaling

Page 3 - 1

Page 31

Specifications Orca 1600 Operation and Maintenance Manual

3.2 Consumables

Film types:

Film diameters:

Core size:

Film widths:

• Pressure sensitive laminates

• Pressure sensitive adhesives

• Low melt laminates

• Thermal laminates

• Thermal adhesives

• Up to a 10 in. roll diameter ( 25.4 cm )

• 3 in. core standard ( 7.62 cm )

• 64 in. maximum pressure sensitive ( 163 cm )

• 62 in. maximum thermal ( 158 cm )

Paper widths:

Mounting thickness:

Safety:

Rewind tubes:

• 63 in. maximum paper width ( 160 cm )

• Up to 1 in. thick ( 2.54 cm ) either direction

• Designed to UL / CSA / CE safety standards

• 3 in. diameter x 66-3/8 in. length (7.62 x 168.59 cm)

Page 3 - 2

Page 32

Section 3.3 Function

SpecificationsOrca 1600 Operation and Maintenance Manual

Speed:

Motor:

Heating capabilities:

Controls:

Heater controls:

• 0 - 15 ft / min ( 0 - 4.6 m / min )

• 2-1/4 horse power drive motor

• Bi-directional D.C. motor

• 68oF - 270oF ( 20oC - 132oC )

• Front control panel

• Rear control panel

• Footswitch

• Independent Cal 3200 control units

Rollers:

Roll design:

• Heat capable upper and lower main rollers

• Driven lower main roller

• Free spinning upper main roller

• Pneumatic controled lower pull roller

• Free spinning upper pull roller

• High release silicone rollers

Page 3 - 3

Page 33

Specifications Orca 1600 Operation and Maintenance Manual

Section 3.4 Electrical

United States and Canada:

Europe:

B.T .U. output:

Heater wattages:

Amperage draw:

• 230 - 240 V AC, 50/60 Hz, single phase, 55 amps.

• 230 - 240 VAC, Wye 3 phase, 25 amps/ phase

• 34,120 B.T .U. / hour

• 5000 watts per heater

• No heat, motor only : 1 - 3 amps

• T op heat and motor : 20 - 23 amps

• Both heat and motor : 40 - 43 amps

D/C voltage used:

A/C voltage used:

AIR

Compressor requirements:

• 24 vdc

• 230 vac ( minimum )

• Filtered air at 2 cubic feet per minute ( cfm ), 50 liters/ minute at a pressure of 70 pounds per square inch ( psi ) ( 500 kPa ).

Page 3 - 4

Page 34

Section 3.5 Dimensions

Weight:

SpecificationsOrca 1600 Operation and Maintenance Manual

Crated:

Uncrated:

Dimensions

Crated:

Uncrated

• 2800 lbs. ( 1270 kg. )

• 2300 lbs. ( 1043 kg. )

• 75 in. (H) x 43 in. (W) x 102 in. (L) ( 191 cm (H) x 109 cm (W) x 259 cm (L) )

• 60 in. (H) x 33 in. (W) x 82 in. (L) ( 152 cm (H) x 84 cm (W) x 208 cm (L) ) Refer to Figure 3.5.1

Nip Height:

• 35 1/5 in. ( 90 cm )

Page 3 - 5

Page 35

Specifications Orca 1600 Operation and Maintenance Manual

Figure 3.5.1 Dimensions

33 in.

( 84 c m )

82 in.

( 208 cm )

60 in.

- T

GBC

( 152 cm )

Page 3 - 6

Page 36

InstallationOrca 1600 Operation and Maintenance Manual

4.0 Installation

GBC Films Group is committed to a program of ongoing product improvement. As a result, we are providing these instructions so you can insure that your new Orca 1600 Laminator is properly and securely unpacked, moved, and installed.

Before an Orca 1600 Laminator can be installed, there are a few requirements that must be met. Make certain that each of the requirements listed in the following pre-installation checklist are met before beginning installation.

CAUTION

Is the environment appropriate for the laminator? The laminator requires a clean, dust and vapor free environment to operate properly . It must not be located where there is air blowing directly on the machine

Have you contacted a certified electrician to both wire the laminator and ensure that adequate power is being supplied, having the appropriate capacity , over current protection and safety lockouts are available?

WARNING

The operating environment must be free of

dust, flammable liquids and vapors. You can

be injured by inhaling chemical vapors.

Failure to follow the pre-installation check

list can result in damage to the laminator.

4.1 Pre-installation

Are doorways and hallways wide enough for the

laminator to be moved to the installation site?

Is there ample room for the laminator?

A work area must be established that allows for

operation in both the front and rear of the

laminator and provides space for efficient material

flow . Figure 4.1.1 illustrates a typical machine

area layout.

WARNING

Vapor build up or stored flammable

liquids can cause a fire. Excessive

dust can damage the laminator.

CAUTION

Do not locate the laminator where air is

blowing directly on the machine. The air

flow can cool the rolls unevenly and result

in poor output quality.

Page 4 - 1

Page 37

Installation Orca 1600 Operation and Maintenance Manual

The laminator requires 230 to 240 vac, 50/ 60 Hz, 55 amps. Or, in Europe only, 3-N phase, 240 vac, 32 amps/ phase.

WARNING

The Orca 1600 Laminator is a large and

heavy piece of equipment. It is necessary to

employ LICENSED R IGGERS ONLY to move the lam inator. The lam inator is not

de sig n e d to b e tip ped u p or sidew a y s in a n y

way. Such action disturbs the exact alignment of the rolling parts of the machine and requ ires extensive realignm en t. You can

be crushed or seriously injured.

For instructions on how to connect power,

proceed to 4.7 Electrical connection in this section.

Page 4 - 2

Page 38

Figure 4.1.1 Suggested Floor Layout

InstallationOrca 1600 Operation and Maintenance Manual

4 ft. x 6 ft.

20 ft.

( 508 ) cm

Air compressor

or air line drop

Electrical cord

drop

8 ft 8 in

( 220 cm )

(101.6 x 152 cm)

W ork table on wheels

Back

3 ft

( 91 c m )

Front

8 ft 8 in

( 220 cm )

4 ft. x 6 ft.

(101.6 x 152 cm)

W ork table on wheels

13 ft

( 330 cm )

Page 4 - 3

Page 39

Installation Orca 1600 Operation and Maintenance Manual

4.2 Know your machine

Before performing any procedure within this manual, it is recommended that you take time to know the parts of your new machine.

Figure 4.2.1 The laminator

Control side

Rear

Figure 4.2.3 Front view

Front

control

panel

Lower unwind

Rewind brake

Cardboard

rewind tube

Middle unwind

Motor

E-STOP

E-CABLE

Leveling

pad

Front

Figure 4.2.2 Top view

Rear table

Pu ll ro lle r s

Upper unwind

ORCA 1600

Pro - Tech

Drive side

Upper unwind brake

Rear table

bracket

Figure 4.2.4 Rear view

E-STOP

Core chuck

Core support

Permanent Id ler

Rear

control

panel

Circuit

breaker

Ma in ro llers

Fro n t ta b le

Table idler

Pressure plate

Page 4 - 4

Ma in ro lle r

shim dial

Castor

Tie bar

Pu ll ro lle r

shim dials

Unwind saddle

Page 40

InstallationOrca 1600 Operation and Maintenance Manual

4.3 Unpacking

INFORMATION

ALL SHIPMENTS ARE EX-WORKS.

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.

INFORMATION

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

note of this on the Bill of Lading.

At our

With regards to your shipping method, use one of the following procedures described to safely and properly unwrap / uncrate your laminator .

4.4 Shrink Wrapped

a) Inspect the machine for any obvious shipping

damages upon receipt.

b) Carefully unwrap the shrink wrap from around

the laminator .

CAUTION

INFORMATION

Depending on the destination and customer

preference, your machine may be shipped in

various ways. The laminator may arrive

shrink wrapped or in a plywood crate on a

skid. Please follow the unpacking procedure

that pertains to your method of shipment.

WARNING

Do not attempt to move the laminator across

The unpacking process requires at least two

people. You can be severely injured, crushed

or cause damage to the laminator.

Do not use a knife or other sharp object to

remove the shrink wrap from around the

laminator. You can cause irreparable

damage to the rollers.

c) With another person, carefully wheel your

Orca 1600 Laminator to the installation site.

WARNING

anything other than a flat level surface

without trained and qualified riggers. You

can be crushed or seriously injured.

Page 4 - 5

Page 41

Installation Orca 1600 Operation and Maintenance Manual

4.5 Crated

WARNING

The Orca 1600 Laminator is a large and

heavy piece of equipment. It is necessary to

employ LICENSED R IGGERS ONLY to move the lam inator. The lam inator is not

de sig n e d to b e tip ped u p or sidew a y s in a n y

way. Such action disturbs the exact alignment of the rolling parts of the machine and requ ires extensive realignm en t. You can

be crushed or seriously injured.

4.5.1 Uncrate the laminator

a) Remove the top of the crate and then the sides

in the order shown in Figure 4.5.1

CAUTION

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

can damage the laminator.

INFORMATION

GBC Film Group's warranty does not

cover malfunction of the equipment due to

mishandling and / or tipping. GBC Films

Group bears no responsibility for personal

injury or damage due to moving the

laminator improperly.

Tools required

• # 2 Phillips head screwdriver

• 7/8” open end wrench or adjustable wrench

• Crow bar

• A second person

INFORMATION

Do not put packing screws on the floor.

They can cause problems when trying to roll

the laminator into position or you can

become injured if stepped on.

CAUTION

A second person must support the side labeled 5 in Figure 4.5.1 It can fall and

damage the laminator or cause harm to you

and others.

Page 4 - 6

Page 42

InstallationOrca 1600 Operation and Maintenance Manual

Figure 4.5.1 Disassembling of the crate

Remove This Side

ORCA 160 0

Pro - Tech

GBC

4.5.3 Moving the laminator

a) Have the laminator removed off of the skid one of

two methods:

1) Rolled off the skid and placed on the floor by licensed riggers using the included ramps. The ramps must be secured utilizing screws

removed from the disassembled crate.

4.5.2 The shrink wrap

a) Gently unwrap the shrink wrap from around the

laminator.

CAUTION

Do not use a knife or other sharp object to

remove the shrink wrap from around the

laminator. You can cause irreparable

damage to the rollers.

WARNING

Do not attempt to use the ramps if they are

not secured to the pallet. Ensure the pallet is

on a flat even surface before attempting to

roll the machine off.

2) Lifted off of the skid with a forklift by positioning the forks where indicated by fork lift decals located on the tie bars on the machine.

b) Move all packing materials to a safe distance.

Page 4 - 7

Page 43

Installation Orca 1600 Operation and Maintenance Manual

b) Remove any plastic strapping and/or packing

paper taped to the rollers.

CAUTION

Do not use a knife or other sharp object to

remove the shrink wrap from around the

laminator. You can cause irreparable

damage to the rollers.

c) Remove all packing materials to a safe distance

from the laminator and dispose of properly .

e) Consider the following when determining where

to locate your machine;

WARNING

Th e op erating en viron m en t m ust b e free of

dust, flammable liquids and vapors. You can

be injured by inhaling chemical vapors.

WARNING

Vapor build up or stored flammable liquids can cause a fire. Excessive dust can damage

the la mina tor .

INFORMATION

About recycling: The crate components can

be reused for shipping the laminator again

or can be disassembled and the wood and

screws recycled. The shrink wrap is not

recyclable, so it must be discarded.

d) Use two people to carefully roll the laminator to

the desired location.

WARNING

Do not attempt to m o v e th e la minato r a c ro ss

anything other than a flat level surface

without trained and qualified riggers. You

can b e cru shed o r seriou sly injured .

CAUTIO N

Do n o t locate the lam ina tor w h ere air is

blow ing directly on the machine. Th e a ir

flow can cool th e rolls un even ly an d resu lt in

poor quality output.

INFORMATION

En su re sufficien t space f or op en ing of the

cabinets for maintenance and servicing.

Page 4 - 8

Page 44

InstallationOrca 1600 Operation and Maintenance Manual

4.6 Accessory pack

Once the Orca 1600 Laminator has been unpacked and moved into final position, open the accessory pack and verify the contents.

Accessory Pack contents

• One T-handle allen wrench ( 475-200 )

• One Zippy knife ( 475-620 )

• One T erry clothe towel ( 475-950 )

• One Operators manual ( 930-061 )

• One roll masking tape ( 475-000 )

• T wo Polyurethane O-rings ( 480-005 )

• One strain relief for main power ( 175-201 )

• One rubber cement pad ( 930320 )

• Four fuses, 3.0A ( 186-200 )

• Four leveling pads ( 475-100 )

4.7 Electrical Connection

The Orca 1600 laminator requires 220 ~ 240 VAC electrical power for proper operation. The power supply may be either single phase or three phase ( five wire or four wire ). For single-phase power, a 55 amp service is required and for three-phase power, 25 amps per phase is required.

The Orca 1600 requires the electrical power cord to be wired directly to the line terminal block located within the control side cabinet.

Before the machine is installed, a qualified electrician must route the proper wiring to the location where the machine will be stationed. The machine then can be connected to the power supply by a qualified electrician following one of the three instructions listed below .

If you are missing any of the items listed above, contact your local service technician or sales representative.

Contacts:

GBC Parts ( 800 ) 790 - 7787

GBC Europe parts 33 - 45 - 535 - 7676

ELECTRICAL

SHOCK

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.

4.7.1 Preparation

a) Ensure the power at the junction box is in the OFF position. Use a voltage meter to verify.

Page 4 - 9

Page 45

Installation Orca 1600 Operation and Maintenance Manual

b) Open the control side cabinet by removing the

four hex button head screws with a 5/32 in. allen wrench.

Bolts

3111

6521

A1A2

3 14 34

9 10

3111

6521

F+P2P3 I1P1 L1F- L2A+A-

A1A2

9 10

7824

3111

6521

A1A2

3 14 34

9 10

3111

6521

A1A2

3111

6521

A1A2

9 10

7824

3111

6521

A1A2

3111

6521

A1A2

+ -

PEB EA

EAEB P

Figure 4.7.1 Single phase ( 3 wire )

Hot LegHot Leg

Blue Wires

Ground

Gound

Wire

Red W ires

L 6 L 4 L 2

L 5 L 3 L 1

Figure 4.7.2 Delta three phase ( 4 wire )

Cut here

Jumper

Bar

Line terminal block

Stra in re lie f

c) Remove the power cable strain relief ( 175-201 )

from the accessory box and install it at the lower rear hole of the control side cabinet.

d) Connect the power cord to the line terminal

block. Refer to the correct Figure for your

connection. Jumper bars may require removing or cutting.

Blue WiresRed W ires

L 6 L 4 L 2

L 5 L3 L 1

Gound

Wire

Terminal

connecter

Jumper Bars

Position

Hot Le

Red Wires

L 6 L 4 L 2

L 5 L 3 L 1

Hot Le

Blue Wires

Hot Le

Ground

Gound

Wire

Jumper Wire

Figure 4.7.3 Wye three phase ( 5 wire )

Blue Wires

Gound

Wire

Remove

Jumper Bars

Red W ires

L 6 L 4 L 2

L 5 L 3 L1

Jumper Bars

Page 4 - 10

Hot Leg

Neutral Leg

Ground

Page 46

InstallationOrca 1600 Operation and Maintenance Manual

e) Turn the junction box power to the ON

position.

f) Verify line voltage with regards to the type of

power being supplied to the laminator at the line terminal block.

ELECTRICAL

SHOCK

On ly a qu alified electrician sho u ld verify the voltage. Yo u can b e severely sh ock ed ,

electrocuted or ca use a f ire.

g) Once the power has been properly connected,

continue with 4.8 Air connection before closing the control side cabinet.

4.8 Air connection

The laminator requires filtered air at 2 cubic feet per minute (cfm), 50 liters/minute at a pressure of 70 pounds per square inch (psi) (500 kPa). The air supply must be clean (free of dirt) and dry . Moisture causes corrosion and particles can block the pneumatic controls. Either problem can cause the laminator to malfunction.

It is the customer’s responsibility to provide appropriate filters and water traps for the air hose before the air is routed to the laminator . GBC suggests that the best approach to the air requirement is to provide a dedicated small compressor for the laminator . A standard light duty 1/2 to 3/4 horse power (1 kW) electric air compressor with 1.5 to 2.5 cfm output with a 5 gallon (20 liter) storage tank is appropriate.

WARNING

Do n o t opera te the m a ch ine w ith th e

control side or drive side cabinet

in th e o p en p o s itio n .

ELECTRICAL

SHOCK

Do not op er a te th e la m inator if th e p ower

cord is damaged or frayed. You can be

severely shock ed , electrocuted o r cau se a

fire. Contact a qu alified electrician to

replace the cor d.

a) Once a quick disconnect is attached to the end of

the hose from the compressor, connect the air to

the air filter located on the machine.

Air filter

Quick-

disconnect

Page 4 - 11

Page 47

Installation Orca 1600 Operation and Maintenance Manual

b) Set the main air in pressure to 70 pounds per

square inch (psi) (500 kPa) by turning the air regulator knob.

100

Regulator

knob

4.9 Installing levelers

Leveling of the machine is a customer option. If you choose not to level the laminator and you encounter output problems, please level the machine and try your application again before calling for technical support. Resting the laminator on the leveling pads will prevent the machine from rolling during set up, operation or servicing.

Tools required

• ( 1 ) 1/2 in. open end wrench

• ( 1 ) 7/8 in. open end wrench

• Four leveling pads ( from the accessory pack )

IN F OR MAT ION

Th e u pp er m a in roller an d the u p per p u ll

rolle r s h o u ld b e in th e ra is ed p o s itio n .

c) Close the control side cabinet and secure with the

factory bolts.

a) Be sure that the machine is placed where you

want it to rest.

b) Secure the four leveling pads onto the four foot

bolts.

c) Use the 1/2 in. wrench on the foot bolt and the

7/8 in. wrench on the leveling pads and tighten

them together.

Page 4 - 12

1/2 Wrench

7/8 Wrench

Page 48

InstallationOrca 1600 Operation and Maintenance Manual

4.10 Leveling

Leveling of the machine is an important step in assuring that the equipment will run at it’s optimal speed and capabilities with little adjustments as possible.

a) Use the foot bolt to raise/ lower the machine so

that the bubble in the leveler is centered.

Center the bubble

c) Place the leveler on the control side frame, not

the top of the cabinet, and level the machine from front to rear.

Place level here

ro - Tech

1/2 in.

Wrench

b) Place the leveler on the lower front tie bar and

level the machine from left to right.

e) Do the same for the drive side.

Place level here

Pro - Tech

GBC

Plac e lev e l h er e

f) Place the leveler on the lower rear tie bar and

level the machine from left to right.

ro - Tec h

g) V erify all sides to confirm that the machine is level.

Page 4 - 13

Page 49

Installation Orca 1600 Operation and Maintenance Manual

4.11 Calibrations

The following calibrations should be performed by a qualified GBC technician before the machine is to be operated. These calibrations may not be performed by the operator . Improper calibrations can result in poor lamination output.

ELECTRICAL

SHOCK

Th ese calibration s req uire th e lam ina tor

to be po w ered u p w h ile the cabin ets

are open ed .

a) The main roller nip is to be calibrated.

b) The pull roller nip is to be calibrated.

c) All three photo-eyes are to be calibrated.

d) The drive chains are to be checked and

tensioned if necessary .

e) Air rate on both set of rollers are to be checked.

f) Safety check and control panel operation checks

are to be performed.

Page 4 - 14

Page 50

Orca 1600 Operation and Maintenance Manual

Operations

5.0 Operations

WARNING

Do not wear ties, loose fit clothing or

dangling jewelry while operating or

servicing the laminator. These items can get

caught in the nip and choke you or you can

be crushed or burned.

This section discusses power on/off, the function of the front control panel, the function of the rear control panel, how to set the temperature, what to do in case of an emergency, film loading and unloading, how to set the main roller nip, how to set the pull roller nip and how to properly shutdown the laminator.

5.1 Power on/ off

ELECTRICAL

SHOCK

Do n o t turn p o w er on if the p ower cord

is damaged or frayed. You can be

severely shocked, electrocuted or

cause a fire. Contact a qualified

electrician to replace the cord .

a) Ensure power from the junction box on the

wall is in the “ON” position.

b) Physically check to confirm that all four E-

STOPs are in the unlatched position.

WARNING

W h en the lam in ator rollers are in

motion, keep hands and fingers

away from the nip of the rollers.

You may be CRUSHED or BURNED!

IN FO RMAT ION

Th e la minato r will only turn o n if

all E-ST OPs are un latched .

c) Turn the circuit breaker on the machine to

the “ON” position.

Off

Page 5 - 1

Page 51

Operations

Orca 1600 Operation and Maintenance Manual

5.2 Front control panel

The control panel on the Orca 1600 Laminator is located at the front operating position of the machine on the left ( control ) side cabinet.

The front control panel enables the operator to control linear footage/ rate display, motor speed, motor direction, motor auto/ stop, top temperature, bottom temperature, main roller pressure and main roller up/ down.

( 1 ) Speed Readout: Displays the speed of the machine and the linear footage total. When the “ R” is displayed, the readout is displaying the rate. When only a numeric value is displayed, the readout is displaying linear footage.

( 3 )Forward / Reverse Switch: determines the motor direction. In the FWD position, the motor will turn in a forward motion. In the REV position, the motor will turn in a reverse direction. In the center position, the motor will not turn at all.

IN FO RMAT ION

Th e cen ter pos ition is to preven t jam m in g

of the m otor when ch an gin g d irections

( 4 ) Auto / Stop Switch: This switch will engage the motor circuitry and disengage the motor circuitry . This is a momentary switch for latching purposes so that two separate switches can serve the same function. See Rear Control Panel for the other location of this switch.

• The “ SEL “ button will toggle the unit between the

two choices of readouts. ( speed rate or linear

footage total )

• The “ RST “ button will reset the linear footage total

whether the display is showing rate or linear footage

total.

R 0 .0

SEL

( 2 )Speed Control Dial: Adjusts the speed of the motor from zero to a maximum speed of 15 feet per minute ( 4.5 meters per minute ). Turn the dial clockwise to increase speed and counter clockwise to reduce speed.

RST

AUTO

STOP

SPEED

FW D

REV

( 5 ) Temperature Control Unit ( Top ): This unit is used to set the desired heating temperature of the top main roller . The display can be programmed to show

F or oC.

CAL 3200

Page 5 - 2

Page 52

Orca 1600 Operation and Maintenance Manual

Operations

( 6 ) Temperature Control Unit ( Bottom ): This

unit is used to set the desired heating temperature of the bottom main roller. The display can be programmed to show oF or oC.

CAL 3200

( 7 ) Top Heater on / off Switch: Turns the temperature controller unit for the upper main roll to on ( I ) or off ( O ).

( 9 ) Main Roll Pressure Adjustment: Adjusts the air pressure supplied to the main roller air cylinders. Pull out on the knob to turn and push in on the knob to lock down.

IN FO RMAT ION

W h en d ecreasin g p ressu re, allow the

pressure g u age to dro p b elow the desired

value, then in crease p ressu re to th e set

pressure d esired . Th is allow s fo r a more

accura te pressu re read ing .

( 10 ) Main Roll Pressure Gauge: Displays the air pressure supplied to the main roller air cylinders.

IN FO RMAT ION

Top tem p eratu re con trol un it on/ o ff

switch must b e o n to t u r n t h e lo wer

temp erature co n trol unit to on .

( 8 ) Bottom Heater on / off Switch: Turns the temperature controller unit for the lower main roll to on ( I ) or off ( O ).

TOP BOTTOM

HEAT

( 1 1 ) Main Roll up / down Switch: When pressed to the down position, the upper main roller lowers. When pressed to the up position, the upper main roller raises.

PRESSURE

P.S .I.

100

ROLLADJ

( 12 ) Main Power Indicator Light: When illuminated, there is electrical power going to the machine.

Page 5 - 3

Page 53

Operations

Figure 5.2.1 Front contr ol panel

PRO TECH ENGINEER IN G D E FOREST WI. U.S.A. (608) 246 - 8844

Orca 1600 Operation and Maintenance Manual

R 0 .0

RST

SPEED

SEL

FW D

REV

MOTOR CONTROLS

CAL 3200

TOP BOTTOM

CAL 3200

AUTO

STOP

LAMINATOR ROLL CONTROLS

MAIN POWE R

HEAT

PRESSURE

P.S.I.

100

ROLLADJ

Page 5 - 4

Page 54

Orca 1600 Operation and Maintenance Manual

Operations

5.3 Rear control panel

The rear control panel enables the operator to control the clutch operation, the upper pull roller operation, the cooling fans and the motor auto/ stop.

( 1 ) Clutch pressure adjustment: Adjusts air pressure supplied to the pneumatic clutch for the lower pull roller. Pull out on the knob to turn and push in on the knob to lock down.

– With a lower pressure supplied to the clutch,

the clutch slips more and the pull rolls pull with

less force.

– With a higher pressure supplied to the clutch,

the clutch slips less or not at all and the pull

rolls pull with a greater force.

( 3 ) Clutch on / off Switch: Engages or disengages air flow to the pneumatic clutch driving the lower pull roller. The lower pull roller is connected to the chain drive system via a pneumatic clutch.

– When the clutch switch is on ( I ), the lower pull roller is engaged with the chain drive system and pulls more or less depending on the clutch pressure adjustment setting.

– When the clutch is off ( 0 ), the clutch is in the “free spin” state. The lower pull roll is disengaged and will not respond to the motor controls.

PRESSURE

ADJ

100

P.S.I.

IN FO RMAT ION

W h en d ecreasin g p ressu re, allow the

pressure g u age to dro p b elow the desired

value, then in crease p ressu re to th e set

pressure d esired . Th is allow s fo r a more

accura te pressu re read ing .

( 2 ) Clutch Pressure Gauge: Displays the air pressure supplied to the pneumatic clutch.

( 4 ) Pull Roll Pressure Adjustment: Adjusts air pressure supplied to the pull roll air cylinders. Pull out on the knob to turn and push in on the knob to lock down.

( 5 ) Pull Roll Pressure Gauge: Displays the air pressure supplied to the pull roll air cylinders.

Page 5 - 5

Page 55

Operations

( 6 ) Pull Roll up / down Switch: Signals the solenoid

air valve for the pull roll air cylinders to shift to the appropriate position to either raise or lower the upper pull roll.

IN FO RMAT ION

W hen an emergency stop feature is activated

an d th e main r o ll is in the up p o si tio n , th e

pu ll r o ll will on ly s ta y in the u p positio n

until the em ergen cy stop fea ture is

deactivated.

Orca 1600 Operation and Maintenance Manual

IN FORMATION

Th e m o tor m u st be en ga ged fo r the co oling

fans to t u r n o n. If th e fa n sw it ch is in th e

"o n " p o s ition, the fa n s will au to matica lly

turn on wh en the motor is engaged.

( 8 ) Auto / Stop Switch: This switch will engage the motor circuitry and disengage the motor circuitry . This is a momentary switch for latching purposes so that two separate switches can serve the same function. See Front Control Panel for the other location of this switch.

PRESSURE

P.S.I.

100

ROLL

ADJ

( 7 ) Cooling Fans on / off Switch: Turns the cooling fans on or off. The cooling fans only operate when the motor circuit is engaged.

AUTO

STOP

COOLING FANS

Page 5 - 6

Page 56

Orca 1600 Operation and Maintenance Manual

Figure 5.3.1 Rear control panel

PRESSURE

ADJ

P.S.I.

Operations

100

PULL ROLL CLUTCH

ADJ

PULL ROLL CONTROLS

COOLING FANS

PRESSURE

P.S.I.

100

ROLL

AUTO

STOP

Page 5 - 7

Page 57

Operations

Orca 1600 Operation and Maintenance Manual

5.4 Setting temperature

To increase or decrease temperature settings,

perform the following steps.

Increase;

IN FORMATION

When requiring top and bottom heat, it is recom m en d ed to set both tem p eratu res to

the s a me set point.

c) Decrease main roller pressure, lower the upper

main roller, set a slow speed and press AUT O to allow the rollers to roll for an even heating surface.

Decrease;

a) Press and hold the asterisk key while pressing

the down key until the desired set point is displayed on the temperature control unit.

CAL 3200

a) Press and hold the asterisk key while pressing

the up key until the desired set point is displayed on the temperature control unit.

225

CAL 3200

INFORMATION

Th e m a xim u m set p oint tem p eratu re

is 270

F ( 132 oC ).

INFORMATION

Th e minim u m set p o in t te m p e ra tu r e

is 32

F ( 0 oC ).

b) Once the desired set point is displayed,

release both buttons.

c) Decrease main roller pressure, lower the upper

main roller, set a slow speed and press AUT O to allow the rollers to cool evenly .

b) Once the desired set point is displayed,

release both buttons.

Page 5 - 8

Page 58

Orca 1600 Operation and Maintenance Manual

Operations

5.5 In case of an emergency

Four E-STOP buttons, two located on the left and right side from the front operating position and two located on the left and right side from the rear operating position. In the event you are unable to reach an E-STOP, a front and rear E-CABLE is installed for your safety .

Rear E-STOP

Rear E-CABLE

Rear E-STOP

b) Resolve the emergency situation.

c) If an E-STOP was depressed, turn the knob

counter clockwise to disengage the E-STOP button. If an E-CABLE was pressed, continue with next step.

Turn

Front E-CABLE

Front E-STOPFront E-STOP

a) Press in on any one of the four E-STOP buttons

or press using your foot on either E-CABLE

in the event of an emergency situation.

Push

d) On the front control panel, press the main roller

UP/ DOWN switch to the UP position.

PRESSURE

Th e u pp er m a in ro ller UP / DOW N switch

resets the ma in ro ller to the correct po sition.

ROLLADJ

100

P.S.I.

IN FO RMAT ION

W hen a safety feature is engaged, the

upper rollers raise and power to

the drive m o tor is rem ov ed.

d) Resume running the laminator.

Page 5 - 9

Page 59

Operations

Orca 1600 Operation and Maintenance Manual

5.6 Film loading/ unloading

The Orca 1600 utilizes a swing out unwind arm for simple loading and unloading of film. Always pay particular attention to which side of the laminate is the adhesive side and which side is the laminate side. The adhesive side should always face away from the face of the rollers.

Po ly -in film Po ly -o u t f ilm

Adhesive

b) Pull up on the clevis pin to the unwind support

saddle you are about to load a roll of film to.

Clevis pin

Unwind support saddle

c) Swing the unwind arm out away from the

machine.

Adhesive

Load a roll of film

a) Adjust the core chucks to fit within the roll of

film being used. The roll of film should be

approximately center of the main rollers. The

core chucks should be close to the edge of the

roll of film.

Ro ll o f film

( Upper unwind shaft shown for illustration purposes )

d) With respect to the adhesive side of the roll,

slide the roll of film onto the unwind arm.

e) Swing unwind arm back into the unwind arm

support saddle and push the clevis pin down.

Core chuck Core chuckCore support

Page 5 - 10

( Upp e r u n w in d s ha ft sh o w n for illus tra tion p u rp o ses )

Page 60

Orca 1600 Operation and Maintenance Manual

Operations

Unloading a roll of film

a) Cut the laminate from the web.

CAUTIO N

Do n o t use an o pen b lade to cu t

the w eb nea r th e rollers.

You ca n p u t cuts into th e rollers!

b) Pull up on the clevis pin.

5.7 Main roller nip

To set the main roller nip for use with substrates can easily be obtained by setting the shim dials on the main roller to the desired opening.

a) Ensure the upper main roller is in the up

position.

INFORMATION

The nip can only be changed with the

upper roller in the up position.

c) Swing the unwind shaft out away from the

laminator.

( Up p e r u n wind s h aft s h o wn fo r illu s tra tio n p u rp o s e s )

d) With a little twist on the roll of film, pull the

roll off of the unwind arm.

b) Turn the shim dial to the desired setting.

( viewe d fro m the to p o f lam ina to r )

Sh im dia ls

Front operating position

c) Adjust main roller pressure for the desired

setting with respect to the substrate being used.

e) If finished, swing the unwind arm back into

its unwind support saddle and push the clevis pin down. If not, follow the Load a roll of

film procedure again from step d).

d) Press the main roller UP/ DOWN switch to

DOWN.

Page 5 - 11

Page 61

Operations

Orca 1600 Operation and Maintenance Manual

5.8 Pull roller nip

T o set the pull roller nip for use with substrates can easily be obtained by setting the shim dials on the pull roller to the desired opening.

a) Ensure the upper pull roller is in the up

position.

INFORMATION

The nip can only be changed with the

upper roller in the up position.

5.9 Shutdown procedure

Perform the steps below to properly shutdown

your machine.

a) Unweb the laminator and clean the rollers as

described in Section 8.2 Cleaning the rollers.

b) Set the left and right shim dials of the main

roller to greater than 1/2 inch ( 1.27 cm ).

b) Turn the shim dial to the desired setting.

Rear operating position

Shim disks

( view e d fro m the to p of laminato r )

c) Adjust pull roller pressure for the desired

setting with respect to the substrate being used.

d) Press the pull roller UP/ DOWN switch to

DOWN on the rear control panel.

IN FO RMAT ION

Th is will pre v en t the main ro llers fr o m

contacting if the a ir shou ld be removed.

c) Set the pull roller shim disk to 1/2 inch.

IN FO RMAT ION

This w ill p re v ent the p u ll r o llers f ro m

contacting if the a ir shou ld be removed.

Page 5 - 12

d) Turn the power ON/ OFF switch on the

laminator to OFF.

Page 62

ApplicationsOrca 1600 Operation and Maintenance Manual

6.0 Applications

The Orca 1600 can accommodate Poly-in or Poly-out films. Poly-out means the adhesive is on the outside of the roll.

The shiny side of clear film must contact the main rollers with the dull sides ( adhesive side ) facing out. Use caution when loading matte or delustered film since both sides appear dull.

The top and bottom rolls of laminating film must be of the same width and be present simultaneously . If performing a single sided lamination process, a craft paper carrier or a substrate of the same width must be used in place of the bottom laminate.

6.1 Temperature chart

The temperature chart is only a starting point for general types of laminates. For optimal output quality , you may have to adjust up or down from the suggested temperature.

IN FO RMAT ION

For o p timal tempera tu r e s ettin g s o f

various laminates, contact your supp lier or sales rep resen tative.

H o t lamin ate s

mil Temperature

Speed

bond paper, E-stat, ink jet

WARNING

Do not wear ties, loose fit clothing or

dangling jewelry while operating or

servicing the laminator. These items can get

caught in the nip and choke you or you can

be crushed or burned.

The process control charts and web diagrams illustrated in this section are reference points only . Parameters will vary with regards to laminate thickness, laminate widths, laminate types, print types, ink or toner types, paper types, environment conditions and operator experience.

3 m il

5 m il

6 m il

10 m il

Gen eral ru le: Sm aller prin ts requ ire m ore

speed or less tem pera ture. L arg er p rints

require less sp eed o r m o re tem per ature.

215 - 220 oF

( 102 - 104

220 - 225

( 104 - 107

225 - 235

( 107 - 113

235 - 245

( 113 - 118

IN FO RMAT ION

C ) F

C )

3 - 7 fpm

3 - 5 fpm

Page 6 - 1

Page 63

Applications

Orca 1600 Operation and Maintenance Manual

6.2 Helpful hints

Pressure sensitive materials

In most cases, a little heat ( 120 oF / 49 oC ) helps the adhesive in pressure sensitive films flow smoothly to prevent what we call “silvering” in the laminate.

The release liner on pressure sensitive films should separate just above the main roller.

IN FO RMAT ION

Use film brake tension to control the

separa tion po int of the r elease liner.

Mounting

Mounting on the Orca 1600 can be achieved from the front operating position using the main rollers or from the rear operating position using the pull rollers. Heat can also assist with mounting, it follows the same hints as pressure sensitive materials.

IN F OR MATIO N

Th e m o un t ad h esive m u st no t exceed 1 in.

the w idth of the substrate. If it does, you

w ill e xp e rie n ce c omplications with th is

application.

Thermal films materials

Clutch pressure may have to be adjusted to obtain a quality output. Some thermal films require cooling to assist with the control of the expansion and contraction of the laminate or image.

INFORMATION

Sp e ed s a n d temper a tu re s will affe c t th e

bond strength of thermal adhesives.

Pressure

Most lamination is performed with 80 psi of pressure on the main rollers, 80 psi on the pull rollers and 80 psi on the clutch. Once again, there are variables that may require some adjustments of the above mentioned pressures.

T ypically the thicker the paper, the more pressure required and for thinner paper ( tissue paper/ light bond paper ) you can use less pressure ( as little as 55 psi ) on the main roller.

When it comes to mounting, the one general “rule” is to not crush the substrate. Most substrates only require about 20-50 psi of pressure, but variables can effect how much pressure is actually needed. ( width, thickness, density , etc. )

IN F OR MA T ION

Not all papers and inks are compatible with

ther mal film s . T e st th e co mbin a tio n s f irst.

INFORMATION

Ex c es siv e pressu r e will cause the

substrate to bow or flatten.

Page 64

ApplicationsOrca 1600 Operation and Maintenance Manual

Brake tension

Brake tension should always be minimal. Brake tension should always be even from the top roll of film to the lower roll of film. Never use excessive amount of brake tension.

IN FORMATION

Excessive brake tension may cause the

imag e to curl. A lw ays u se the minimum

amoun t of brake for the job.

General

6.3 Temp conversion chart

A temperature conversion chart has been included

for your convenience. Use Figure 6.3.1 T emperatur e conversion chart on page 6-4 for converting temperatures from oF to oC and vice a versa.

CAUTIO N

Excess pressure can damage the laminating

rollers. Alway s u se the m in imu m roll

pressure n ecessa ry to co m p lete the task.

IN FO RMAT ION

Never stop the lam inator when an image is

within the n ip of either set of ro llers.

IN FO RMAT ION

Lam inates and papers should always be

stored in a co n trolled en virom en t.

Page 6 - 3

Page 65

Applications

Figure 6.3.1 Temperature conversion chart

Orca 1600 Operation and Maintenance Manual

F 68 20 69 20.6 70 21.1 71 21.7 72 22.2 73 22.7 74 23.3 75 23.9 76 24.4 77 25 78 25.6 79 26.1 80 26.7 81 27.2 82 27.8 83 28.3 84 28.9 85 29.4 86 30 87 30.6 88 31.1 89 31.7 90 32.2 91 32.8 92 33.3 93 33.9 94 34.4 95 35 96 35.6 97 36.1 98 36.7 99 37.2

100 37.8 101 38.3 102 38.9 103 39.4 104 40 105 40.6 106 41.1 107 41.7 108 42.2 109 42.8 110 43.3 111 43.9 112 44.4

= = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = =

F 113 45 114 45.6 115 46.1 116 46.7 117 47.2 118 47.8 119 48.3 120 48.9 121 49.4 122 50 123 50.6 124 51.1 125 51.7 126 52.2 127 52.8 128 53.3 129 53.9 130 54.4 131 55 132 55.6 133 56.1 134 56.7 135 57.2 136 57.8 137 58.3 138 58.9 139 59.4 140 60 141 60.6 142 61.1 143 61.7 144 62.2 145 62.8 146 63.3 147 63.9 148 64.4 149 65 150 65.6 151 66.1 152 66.7 153 67.2 154 67.8 155 68.3 156 68.9 157 69.4

= = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = =

F 158 70 159 70.6 160 71.1 161 71.7 162 72.2 163 72.8 164 73.3 165 73.9 166 74.4 167 75 168 75.6 169 76.1 170 76.7 171 77.2 172 77.8 173 78.3 174 78.9 175 79.4 176 80 177 80.6 178 81.1 179 81.7 180 82.2 181 82.8 182 83.3 183 83.9 184 84.4 185 85 186 85.6 187 86.1 188 86.7 189 87.2 190 87.8 191 88.3 192 88.9 193 89.4 194 90 195 90.6 196 91.1 197 91.7 198 92.2 199 92.8 200 93.3 201 93.9 202 94.4

= = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = =

F 203 95 204 95.6 205 96.1 206 96.7 207 97.2 208 97.8 209 98.3 210 98.9 211 99.4 212 100 213 100.6 214 101.1 215 101.7 216 102.2 217 102.8 218 103.3 219 103.9 220 104.4 221 105 222 105.6 223 106.1 224 106.7 225 107.2 226 107.8 227 108.3 228 108.9 229 109.4 230 110 231 110.6 232 111.1 233 111.7 234 112.2 235 112.8 236 113.3 237 113.9 238 114.4 239 115 240 115.6 241 116.1 242 116.7 243 117.2 244 117.8 245 118.3 246 118.9 247 119.4

= = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = =

F 248 120 249 120.6 250 121.1 251 121.7 252 122.2 253 122.8 254 123.3 255 123.9 256 124.4 257 125 258 125.6 259 126.1 260 126.7 261 127.2 262 127.8 263 128.3 264 128.9 265 129.4 266 130 267 130.6 268 131.1 269 131.7 270 132.2 271 132.8 272 133.3 273 133.9 274 134.4 275 135 276 135.6 277 136.1 278 136.7 279 137.2 280 137.8 281 138.3 282 138.9 283 139.4 284 140 285 140.6 286 141.1 287 141.7 288 142.2 289 142.8 290 143.3

= = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = =

Page 66

6.4 Charts and diagrams

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 1600 as well as completed charts for the basic operations of the laminator. The process control charts should be kept in this manual or in a book close to the laminator.

ApplicationsOrca 1600 Operation and Maintenance Manual

The Orca 1600 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 completed process control charts included in this section are based on GBC films, GBC boards and typical prints. Charts and diagrams start on page 6-5.

Page 6 - 5

Page 67

Applications

Orca 1600 Operation and Maintenance Manual

Chart - 0

PROCESS CONTROL CHART

Orca 1600 L am inator

MATERIALS MENU

Process: Top material: Bottom ma terial: O th e r mate ria l(s):

FRONT CONTROL PANEL SETTINGS

Spe e d ( ft/ m in ): Roller direction: FWD REV M a in ro lle r position : UP DOW N M a in r o lle r s h im: M a in ro lle r pr es s u re: Top heater pow er: ON OFF Bottom heater power: ON O FF Top heater temp erature: Bottom h eater tem perature:

REAR CONTROL PANEL SETTINGS

Pu ll ro lle r c lu tc h : O N OFF Pu ll ro lle r p o s itio n : UP D OW N Pull roller clutch pressure: Pu ll ro lle r s h im:

Pu ll ro lle r p re s s u re : Cooling fans: ON OFF

SPECIAL INSTRUCTIONS

Comments:

Reference diagram: Diagram -

RELATED DIAGRAM

Page 68

Diagram - 0

ApplicationsOrca 1600 Operation and Maintenance Manual

Page 6 - 7

Page 69

Applications

Orca 1600 Operation and Maintenance Manual

Chart - 1

PROCESS CONTROL CHART - 1

Orca 1600 L aminator

MATERIALS MENU

Process: 1 Pass mounting Top material: Bo tt o m m a te rial: Other m aterial(s): Substrate, thermal mou nt adh esive and release liner or craft paper

FRONT CO NTRO L PANEL SETTINGS

Sp e e d ( ft/ min ): 3 ( 9 0 cm/ m in ) R o lle r d ir e c t io n: FWD R E V Main roller pos it io n: U P DOWN Main roller shim: S u bstra t e t h ic k nes s M ain roller pressu re: 20 - 40 psi Top heater power: ON OFF B ottom heater pow er: ON OFF Top heater tem perature: 230-240 oF ( 110-115 oC ) B ottom heater temp erature: 32 oF ( 0 oC )

REAR CONTROL PANEL SETTINGS

Pull rol le r c l u tch: ON O F F P u ll r o lle r p osition: UP DOWN Pull roller clutch pressure: N/A Pull rol le r s him : N/A

Pull roller pressure: N/A Cooling fans: ON OFF

SPECIAL INSTRUCTIONS

Comments:

the ink from blistering o r staining the rollers. Speed an d tem p erature are critical factors in this process

since the heat must penetrate through the release liner ( if being used ), through the print, heat up the

If you are using a heat sensitive print, position the release liner over the im age to prevent

thermal m ou nt adh esive eno ug h to b on d with the su bs trate. All hints for m o un ting and therm al app ly.

Reference diagram: Diagram - 1

RELATED DIAGRAM

Page 70

Thermal mount

Release liner

ApplicationsOrca 1600 Operation and Maintenance Manual

Diagram - 1

HOT

Substrate

COLD

Page 6 - 9

Page 71

Applications

Orca 1600 Operation and Maintenance Manual

Chart - 2

PROCESS CONTROL CHART - 2

Orca 1600 L aminator

MATERIALS MENU

Process: PSA D ecaling To p materia l: P S A lamina te Bottom material: PSA m ount adhesive Oth e r m a terial(s): Prints

FRONT CO NTRO L PANEL SETTINGS

Sp e e d ( ft/ min ): 3 - 5 ( 9 0 - 1 52 c m/ m in ) R o lle r d ir e c t io n: FWD R E V Main roller pos it io n: U P DOWN Main roller shim: 0 nip Main roller pres s ure: 8 0 ps i Top heater power: ON OFF B ottom heater pow er: ON OFF Top heater tem perature: 120 oF ( 49 oC ) Bottom heater tempe rature: 32 oF ( 0 oC )

REAR CONTROL PANEL SETTINGS

Pull rol le r c l u tch: ON O F F P u ll r o lle r p osition: UP DOWN Pull roller clutch pressure: 80 psi Pull rol le r s him : 0 n i p

Pull roller pressure: 80 psi Cooling fans: ON OFF

SPECIAL INSTRUCTIONS

Comments:

Sp e e d will vary with th e o p e ra to rs c o mfort a b ility to fe e d th e p r int s in to the la mina to r. If th e o u tp ut is curling , adjust the brake tension on the roll of film o r m ou nt ad hesive bu t w atch the release liner

Even though it is PSA film, h e a t will as sist the b o nding a nd flow o f a d hes iv e on t h e prin t.

se p aration poin t s o th at it re main s jus t a b ove the to p m a i n r o lle r . A d just pres s ures a s nec e s s a r y f o r quality output.

Reference diagram: Diagram - 2

RELATED DIAGRAM

Page 72

Diagram - 2

Release

liner

ApplicationsOrca 1600 Operation and Maintenance Manual

PSA f ilm

Ro ll o f p rints

( roll to r o ll o p t io n )

PSA mount

adhesive

WARM

COLD

( op tional )

Finished

product

rewind

( op tional )

PSA mount

adhesive

Output

Page 6 - 11

Page 73

Applications

Orca 1600 Operation and Maintenance Manual

Chart - 3

PROCESS CONTROL CHART - 3

Orca 1600 L aminator

MATERIALS MENU

Process: M ounting a PSA decal Top material: Bo tt o m m a te rial: Other m aterial(s): Substrate, thermal mou nt adh esive and release liner or craft paper

FRONT CO NTRO L PANEL SETTINGS

Sp e e d ( ft/ min ): 3 ( 9 0 cm/ m in ) R o lle r d ir e c t io n: FWD R E V Main roller pos it io n: U P DOWN Main roller shim: S u bstra t e t h ic k nes s M ain roller pressu re: 20 - 40 psi Top heater power: ON OFF B ottom heater pow er: ON OFF Top heater tem perature: 120 oF ( 49 oC ) Bottom heater tempe rature: 32 oF ( 0 oC )

REAR CONTROL PANEL SETTINGS

Pull rol le r c l u tch: ON O F F P u ll r o lle r p osition: UP DOWN Pull roller clutch pressure: N/A Pull rol le r s him : N/A

Pull roller pressure: N/A Cooling fans: ON OFF

SPECIAL INSTRUCTIONS

Comments:

bonding strength. Be sure to keep the decal nicely wrapped around the upper m ain roller as the decal is fed through t h e m a in r o ller nip. Rem e mb e r, do n ot st o p the lam in a t o r whil e the p ri n t is tr a v e ling through the nip. All hints for mounting and thermal apply.

U s in g a litt le h eat will as sist the a d hes iv e f lo w o f th e de c a l wh ic h in t u r n will h e lp the

Reference diagram: Diagram - 3

RELATED DIAGRAM

Page 74

Ho ld d e c al h e re

ApplicationsOrca 1600 Operation and Maintenance Manual

Diagram - 3

Decal

Release liner

Substrate

WARM

COLD

Page 6 - 13

Page 75

Applications

Orca 1600 Operation and Maintenance Manual

Chart - 4

PROCESS CONTROL CHART - 4

Orca 1600 L aminator

MATERIALS MENU

Process: Th erm al Decaling To p materia l: 3 mil thermal lamina te Bottom material: PSA m ount adhesive Oth e r m a terial(s): Prints

FRONT CO NTRO L PANEL SETTINGS

Sp e e d ( ft/ min ): 3 - 5 ( 9 0 - 1 52 c m/ m in ) R o lle r d ir e c t io n: FWD R E V Main roller pos it io n: U P DOWN Main roller shim: 0 nip Main roller pres s ure: 8 0 ps i Top heater power: ON OFF B ottom heater pow er: ON OFF Top heater tem perature: 220-225 oF ( 105-107 oC ) B ottom heater temp erature: 32 oF ( 0 oC )

REAR CONTROL PANEL SETTINGS

Pull rol le r c l u tch: ON O F F P u ll r o lle r p osition: UP DOWN Pull roller clutch pressure: 80 psi Pull rol le r s him : 0 n i p

Pull roller pressure: 80 psi Cooling fans: ON OFF

SPECIAL INSTRUCTIONS

Comments:

Sp e e d will vary with th e o p e ra to rs c o mfort a b ility to fe e d th e p r int s in to the la mina to r. If th e o u tp ut is curling , adjust the brake tension on the roll of film o r m ou nt ad hesive. Adjust pressures as necess ary

If using other than a 3 m il thermal film, use the Te m p erature chart from Section 6.1 .

to o btain a q uality o utp u t. C oolin g fans may h elp, if not r u n w it h c ooling fa n s O F F.

Reference diagram: Diagram - 4

RELATED DIAGRAM

Page 76

Diagram - 4

ApplicationsOrca 1600 Operation and Maintenance Manual

Th e rm al film

Ro ll o f p rints

( roll to r o ll o p t io n )

PSA mount

adhesive

HOT

COLD

( op tional )

Finished

product

rewind

( op tional ) PSA mount

adhesive

Output

Page 6 - 15

Page 77

Applications

Orca 1600 Operation and Maintenance Manual

Chart - 5

PROCESS CONTROL CHART - 5

Orca 1600 L aminator

MATERIALS MENU

Process: M o un ting of a therma l decal ( PSA decal will work for this process as w ell ) Top material: Bo tt o m m a te rial: Other m aterial(s): Substrate, therm al decal or PSA d ecal

FRONT CO NTRO L PANEL SETTINGS

Sp e e d ( ft/ min ): 3 - 5 ( 9 0 - 1 52 c m/ m in ) R o lle r d ir e c t io n: FWD R E V Main roller pos it io n: U P DOWN Main roller shim: N /A Main roller pres s ure: N/A Top heater power: ON OFF B ottom heater pow er: ON OFF Top heater tem perature: 32 oF ( 0 oC ) Bottom heater tempe rature: 32 oF ( 0 oC )

REAR CONTROL PANEL SETTINGS

Pull rol le r c l u tch: ON O F F P u ll r o lle r p osition: UP DOWN Pull roller clutch pressure: 80 psi Pull roller shim: Thicknes s of sub strate

Pull roller pressure: 20 - 40 psi Cooling fans: ON OFF

SPECIAL INSTRUCTIONS

Comments:

m a in ro lle rs a re t o o hot ( <1 2 5 wrapped around the upper pull roller. Use comfortable operating speed. All hints for mounting apply.

This process is illustrated from the rear operating po sition because w e are assuming the

F or <52 oC ) f o r mounting purpos e s . Be s ure to ke e p t h e dec a l nice ly

Reference diagram: Diagram - 5

RELATED DIAGRAM

Page 78

Diagram - 5

ApplicationsOrca 1600 Operation and Maintenance Manual

Decal

Ho ld d e c al h e re

HOT

COLD

Release liner

Substrate

Page 6 - 17

Page 79

Applications

Orca 1600 Operation and Maintenance Manual

Chart - 6

PROCESS CONTROL CHART - 6

Orca 1600 L aminator

MATERIALS MENU

Process: Th erm al Encap sulation To p materia l: 3 mil thermal lamina te Bo tt o m m a te rial: 3 mil thermal lamina te Oth e r m a terial(s): Prints

FRONT CO NTRO L PANEL SETTINGS

Sp e e d ( ft/ min ): 3 - 5 ( 9 0 - 1 52 c m/ m in ) R o lle r d ir e c t io n: FWD R E V Main roller pos it io n: U P DOWN Main roller shim: 0 nip Main roller pres s ure: 8 0 ps i Top heater power: ON OFF B ottom heater pow er: ON OFF Top heater tem perature: 220-225 oF ( 105-107 oC ) B ottom heater temp erature: 220-225 oF (1 0 5 -10 7 oC)

REAR CONTROL PANEL SETTINGS

Pull rol le r c l u tch: ON O F F P u ll r o lle r p osition: UP DOWN Pull roller clutch pressure: 80 psi Pull rol le r s him : 0 n i p

Pull roller pressure: 80 psi Cooling fans: ON OFF

SPECIAL INSTRUCTIONS

Comments:

Sp e e d will vary with th e o p e ra to rs c o mfort a b ility to fe e d th e p r int s in to the la mina to r. If th e o u tp ut is curling , adjust the brake tension on the roll of film(s). Adjust pressures, speed and tem pe rature as

If using other than a 3 m il thermal film, use the Te m p erature chart from Section 6.1 .

ne c ess a ry to obtain a q uality o utput. C o oling fan s m a y h e lp, if n o t , run with c o oling fans OFF .

Reference diagram: Diagram - 6

RELATED DIAGRAM

Page 80

Diagram - 6

ApplicationsOrca 1600 Operation and Maintenance Manual

Th e rm al film

Ro ll o f p rints

( roll to r o ll o p t io n )

Thermal

film

HOT

( op tional )

Finished

product

rew ind

( op tional )

Th e rm al film

Output

Page 6 - 19

Page 81

Applications

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Orca 1600 Operation and Maintenance Manual

Page 82

TroubleshootingOrca 1600 Operation and Maintenance Manual

7.0 Troubleshooting

WARNING

Do not wear ties, loose fitting clothing or

dangling jewelry while operating or

servicing the laminator. These items can get

caught in the nip and choke you or you can

be crushed or burned.

As an operator, you can perform some simple troubleshooting in attempt to correct your typical output type problems. Use the easy to follow guide for assistance.

Problem: D waves in the image but not in the laminate

Hints: • Check paper tension

• Check relative moisture content of the paper

7.1 Wave problems

The following is a list of common output wave problems you may encounter .

The arrow along the length of the output represents the direction of feed ( travel ).

INFORMATION

For optimal temperature settings of

various laminates, contact your

supplier or sales representative.

Problem: D W aves in the laminate

Hints: • Check the roller pressures

• Check the main roller nip settings

• Check the pull roller nip settings

Page 7 - 1

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T roubleshooting Orca 1600 Operation and Maintenance Manual

Problem: Straight waves in the output

Hints: • Check operational settings for materials

being used.

• Check clutch pressure.

Problem: Angled waves in the output on both sides

Hints: • Check for insufficient main roller pressure

• Check for insufficient pull roller pressure

• Check the main roller nip settings

• Check the pull roller nip settings

Problem: W aves on only one side of the output

Hints: • Check the nip setting of main rollers

• Check the nip setting of pull rollers

• Check for even paper tension

Problem: Indent waves in output after the pull rollers

Hints: • Insufficient cooling time

• Allow output to cool before handling

• Check operating temperatures of material

Page 7 - 2

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TroubleshootingOrca 1600 Operation and Maintenance Manual

7.2 Film problems

The following is a list of common film problems you may encounter.

For definitions of terminologies, please refer to

7.4 Glossary of terminology.

7.2.1 Thermal laminates

Problem: Blistering within the image

Hints: • Increase the speed

• Decrease the operating temperature

• Allow a longer drying time for the image

7.2.2 Pressure sensitive

Problem : Silvering in the laminate

Hints : • Add 100 - 120oF ( 37 - 49oC ) to the

temperature

• Increase pressure to laminating rollers

Problem : Tunneling in finished product

Hints : • Print should be wound image side out.

• Do not roll tightly

• Do not roll at all.

Problem : Image creases when mounting

Problem: Coiling or curling of encapsulated images

Hints: • Balance the upper and the lower brake

tension

• Make sure set point temperatures are the same

• Change the chill idler configuration ( if applicable )

Problem: Silvering in the laminate

Hints: • Decrease the speed

• Increase the operating temperature

Problem: Delamination

Hints: • Check operating temperatures

• Check operating speed

• Laminate compatibility with ink

• Ink compatibility with paper

Hints : • Press down on leading edge from center outwards.

• Be sure image is conformed to the roll

• Use a speed you are comfortable with

• Be sure even tension is supplied to the image

Problem: Delamination

Hints: • Check operating pressures

• Check operating speed

• Laminate compatibility with ink

• Ink compatibility with paper

Problem: Coiling or curling of output

Hints: • Balance the upper and the lower brake

tension

• Change the chill idler configuration ( if applicable )

Page 7 - 3

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T roubleshooting Orca 1600 Operation and Maintenance Manual

7.3 Machine problems

Once the Hints are all checked, and your problem

still exists, a service call must be placed for a qualified service personnel to fix the problem.

Y ou may do this by dialing 1 ( 800 ) 790 - 7787. This will connect you with GBC National Service dispatch . Y ou will be required to give the serial number of your machine when placing a service call.

A space below has been provided to keep this number readily available if and when needed.

Problem : No control panel functions

Hints : • Ensure an E-STOP has not been pushed

down

• Reset the main roller UP/ DOWN switch.

• Confirm that the MAIN POWER is to the ON position.

• Be sure power is supplied to the laminator

Problem : I can only operate using the footswitch.

Hints : • Ensure nothing is blocking the PHOTO-EYE.

My Orca 1600 Laminator serial # is :

At no time does GBC Films Group suggest or recommend that you attempt to fix the machine by opening the cabinets or covers yourself.

WARNING

Do not wear ties, loose fitting clothing or

dangling jewelry while operating or

servicing the laminator. These items can get

caught in the nip and choke you or you can

be crushed or burned.

Problem : I press AUTO and the motor will not turn.

Hints : • Ensure nothing is blocking the PHOTO-EYE.

• Ensure an E-STOP has not been pushed down

• Ensure the FWD/ REV switch is not in the middle position.

Problem : Jerking, stuttering, or excessive noise from the laminator.

Hints : • Check for excessive brake tension

• Confirm that the rolls of laminate are on correctly .

Page 7 - 4

• Place a service call.

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TroubleshootingOrca 1600 Operation and Maintenance Manual

7.4 Glossary

The glossary can help you in understanding some of the terminology used when referring to the laminator, applications, or troubleshooting aspects of the machine.

Blistering

A condition where the paper coating is bubbled up from the image paper causing a “blister”. It is created by using excessive heat during the lamination process. Blistering is most commonly found with photographic and ink jet media.

Coiling

A term used to describe an image rolling up on itself. This is caused by differences in the brake tension used between the upper and lower laminates during and application process.

Cold laminate

Film that does not require heat to activate the adhesive. Please see P .S.A. for more information.

D waves

A term used to describe a wave pattern caused, generally , by incorrect paper tension.

Bond strength

Refers to one of three conditions; 1) the anchor strength of adhesive to laminate substrate, 2) the anchor strength of the laminating film to the product that has been laminated, or 3) when two layers of film are laminated together, the strength of the adhesive to adhesive bond.

Center mount

A mounting technique where an image is mounted centrally on a substrate to provide a decorative border.

Clutch tension

The tension that is applied to the laminated material between the main and pull rolls. This tension is applied by having the pull rolls turn faster than the main rolls, and then having some form of clutching or torque limiting applied to the pull rolls. This tension is important for maintaining a smooth flat finished image.

Delamination

Refers to either one of two conditions; 1) the adhesive separating from the laminate substrate, or 2) the laminate separating from the product being laminated.

Edgewrap

A mounting technique where the image wraps around the edges of the mounting substrate so as to provide a finished edge.

Encapsulation

When an image is completely encased in laminating film, it is encapsulated. A border of laminate on laminate exists around the perimeter of the product.

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T roubleshooting Orca 1600 Operation and Maintenance Manual

Film

A two part material consisting an adhesive layer and a substrate. The adhesive and the substrate may or may not be clear . This is the material used for lamination. Please refer to laminate.

Foamboard

A material commonly used as a mounting substrate. It is made up of foam sandwiched between two layers of paper, or paper like media.

Inkjet

A term used to describe a type of printing where an ink is projected topically onto a paper or paper like media. This is a noncontact form of printing.

Media

T erm used to describe the materials used to print

an image, i.e. the papers, inks, toners, etc.

Mount adhesive

A term used to describe a two sided pressure sensitive adhesive used in mounting images to various substrates. This material can come with one or two release liners and may be optically clear for face mounting applications.

Mount tissue

A thermally activated mount adhesive used in either a vacuum or roll type laminator. Primarily used for mounting bond type papers to porous substrates.

Craft paper

A strong brown paper commonly used for single

sided applications.

Laminate

A two part material consisting an adhesive layer and a substrate. The adhesive and the substrate may or may not be clear. This is the material used for lamination.

Main rollers

These are the rolls that perform the actual lamination. They are rolls capable of being heated in thermal roll laminators and are usually larger in diameter than the pull rolls.

Nip

The interrelationship of any two rolls. The distance between the closest points of the two rolls is referred to as the nip of the rolls.

Outgassing

The term that describes the phenomenon where the heat from the laminating process turns components of the printed media into a gas. This is seen as a cloudy or murky finished image. It can also be caused by a chemical incompatibility between the overlaminate’s adhesive and the printed media.

Page 7 - 6

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Pull rollers

TroubleshootingOrca 1600 Operation and Maintenance Manual

adhesive.

Silvering

These rolls provide tension of the laminated media. T ensioning of the laminated media helps to make it flat and smooth. In most laminators they may also be used for cold mounting and laminating applications. Usually these rolls are of smaller diameter than the main rolls.

P .S.A.

Stands for Pressure Sensitive Adhesive. An adhesive that requires no heat to activate, only pressure. It is employed by removing a protective release liner and then pressed onto the material to be laminated. This type of film is commonly used on materials that are temperature sensitive.

Release liner

A term used to describe one of two occurrences;

1) air bubbles trapped between the product and a thermal laminate, generally caused by insufficient heat being applied by the laminator or 2) the adhesive is not fully activated in a pressure sensitive film, which will disappear once the adhesive is fully activated. This activation process can be sped up if a small amount of heat is applied during the application.

Substrate

The material to which an adhesive is to be bonded. In film, the substrate is the polyester and in mounting, the substrate is the material being mounted to.

A coated paper or other media used to protect

the adhesive side of a pressure sensitive material.

Rewind

A system that rolls up media. The rewind tubes

used on the Orca 1600 laminator is a prime example.

Scarring

The visual effect of folding papers or laminates and breaking the surface. When done to a printed material it will be seen as a white crack in the image.

Second surface

T unneling

When a laminated image is rolled up for any period of time and the laminate separates from the image. Generally in a pattern that follows the direction the laminated image was rolled up in. This is very common with pressure sensitive laminates and finished products that have been wound tightly .

Unwind

A system that unwinds media. Unwinds are used on all laminators to dispense laminate for lamination.

Web

A term to denote the back side of a substrate. Commonly referenced when discussing front mounted images to a clear substrate with an optically clear mount

The path that rolled media unwinding from a supply

roll takes through a machine or array of rollers.

Page 7 - 7

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Page 7 - 8

Page 90

MaintenanceOrca 1600 Operation and Maintenance Manual

8.0 Maintenance

GBC Films Group laminators require minimal maintenance. However, regular maintenance is essential to keep any piece of precision machinery at peak performance. A maintenance schedule and a section of procedures are included in this section.

WARNING

Do not wear ties, loose fit clothing or

dangling jewelry while operating or

servicing the laminator. These items can get

caught in the nip and choke you or you can

be crushed or burned.

8.1 Maintenance Schedule

INFORMATION

Below is a recommended maintenance

schedule. Before performing any of the steps

listed, read through the procedures first.

Please follow the instructions pertaining to

the step you are performing.

Daily

• Clean the rollers

( See cleaning in this section )

• Inspect the electrical cord for damage.

( If damaged, you should replace or repair it immediately )

INFORMATION

Improper maintenance, can

result in poor output quality.

ELECTRICAL

SHOCK

Remove power from the laminator before

servicing. You can be severely shocked,

electrocuted or cause a fire.

• Inspect the footswitch cord for damage.

( If damaged, you should replace or repair it immediately )

Monthly

• Adjust the nip if needed.

( performed by service technician )

• Check the chain tension.

( performed by service technician )

• Inspect the area around the laminator for possible hazards

( dust buildup, combustible items stored too close, etc. )

Page 8 - 1

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Maintenance Orca 1600 Operation and Maintenance Manual

Semi-Annual

• Lubricate the grease fittings, chain, and gears.

( performed by service technician )

• Check wire termination tightness.

( performed by service technician )

Service work performed by a service technician must be qualified to work on GBC equipment.

The word qualified is defined as;

Qualified ;

8.2 Cleaning the rollers

Tools required

• Adhesive coated boards ( picks up dust and particles off of the rolls )

• Protective rubber gloves ( This will protect your hands from the isopropyl alcohol )

• 80% isopropyl alcohol ( a mild dishwashing detergent and water may be used instead )

• Rubber cement eraser ( a belt sander dressing block may be used instead )

• Several 100% cotton terry cloths ( best for lint free cleaning )

• Any engineer that has experience with electrical and mechanical design of lamination equipment. The engineers should be fully aware of all aspects of safety with regards to lamination equipment.

• Any GBC T echnician, GBC Specialist, and / or GBC Films Group T echnician that has been through the GBC Pro-T ech service training course.

CAUTIO N

Use o nly isop rop yl alcoh ol or ru b b er cem en t

eraser to clean th e rollers. Ha rsh chemicals

like toluene, aceton e, or MEK can d estroy

the silicone covering of th e rolls.

CAUTIO N

Exer cise care w h en cleanin g the la m inating

rolle rs with 80 % is op r o p y l a lco h o l:



Us e o nly in a well ve n tila ted area

W ear rubber gloves

Use o nly on co ol rolls

Page 8 - 2

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MaintenanceOrca 1600 Operation and Maintenance Manual

8.3 Dust - Pre-coated boards

a) The main rollers must be below 110 oF ( 43 oC ).

<110

CAL 3200

b) Set the nip of the rollers to the thickness of the

adhesive coated boards.

<110

CAL 3200

8.4 Dirt and PSA adhesive Alcohol and cloth

a) Allow the laminator to cool slightly to no higher

than 110 oF ( 43 oC ).

<110

CAL 3200

CAUTIO N

<110

CAL 3200

c) Set the roller pressure to which ever roller you

are cleaning to 20 - 40 psi..

d) Align the adhesive coated board in front of the

area on the roller to be cleaned.

e) Using the footswitch, run the adhesive coated boards through the rollers.

f) Perform steps d) and e) again.

CLEANING HEATED ROLLERS CAN

IGNITE THE FUMES!

b) Set the machine direction to FWD when cleaning

the pull rollers. Set the machine direction to REV when cleaning the main rollers.

FWD

REV

( if cleaning pu ll rollers )

FWD

REV

( if cleaning

main rollers )

g) Do this as many times as needed to clean the

laminator rolls.

c) Remove the front table and table idler to gain more

access to the main rollers or remove the rear table to gain more access to the pull rollers.

Page 8 - 3

Page 93

Maintenance Orca 1600 Operation and Maintenance Manual

d) Set a slow speed of less than 3 ft/ min. ( 91 cm/

min. ).

e) Put on the rubber gloves and use the isopropyl

alcohol and terry cloth towel to rub where the dirt is on the rollers.

CAUTIO N

Ex c es siv e pressu r e c an des tro y th e silico n e

layer by pressing to hard or scrubbing

too long in one spot.

8.5 Thermal adhesive

a) Allow the laminator to cool slightly, no higher

than 110 oF ( 43 oC ).

<110

CAL 3200

CAUTIO N

<110

CAL 3200

IN FO RMAT ION

Keep the terry cloth tow el k ind of d am p to

mak e th e rub b ing of the roller sm ooth .

f) Use the footswitch to rotate the roller to a new

spot to clean.

g) Do this as many times as needed to clean the

laminator rolls.

CLEANING HEATED ROLLERS CAN

IGNITE THE FUMES!

b) Set the machine direction to FWD when cleaning

the pull rollers. Set the machine direction to REV when cleaning the main rollers.

FW D

REV

( if cleaning pull ro lle rs )

FW D

REV

( if cleaning

m ain r o lle r s )

Page 8 - 4

c) Remove the front table and table idler to gain more

access to the main rollers or remove the rear table to gain more access to the pull rollers.

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MaintenanceOrca 1600 Operation and Maintenance Manual

d) Set a slow speed of less than 3 ft/ min. ( 91 cm/

min. ).

CAUTIO N

Do NO T pick or pull heat activated adhesive

off the rolls w h en th ey a re cold. Y o u ca n

cause irrepa rab le da m ag e to the

lam inating r ol ls.

e) Put on the rubber gloves and use the rubber

cement eraser to bead up the adhesive.

8.6 Clean the laminator

ELECTRICAL

SHOCK

Remove power from the laminator before

cleaning. You can be severely shocked,

electrocuted or cause a fire.

a) Use a damp cotton terry cloth ( water only ),

clean the exterior of the laminator.

f) Use the footswitch to rotate the roller to a new

spot to clean.

g) Do this as many times as needed to clean the

laminator rolls.

CAUTION

Excessive pressure can destroy the silicone

layer by pressing to hard or scrubbing

too long in one spot.

c) Wipe away the beads with isopropyl alcohol

and a cotton terry cloth.

b) If water is not strong enough, you may use a

mild dishwashing detergent with water and a cotton terry cloth.

ELECTRICAL

SHOCK

Do not use liquid or aerosol cleaners on the

laminator. Do not spill liquid of any kind on

the laminator. You can be severely shocked,

electrocuted or cause a fire. Use only a damp

cloth for cleaning unless other wise

specified.

Page 8 - 5

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Maintenance Orca 1600 Operation and Maintenance Manual

8.7 Clean the control panels

ELECTRICAL

SHOCK

Remove power from the laminator before

cleaning. You can be severely shocked,

electrocuted or cause a fire.

a) Use a terry cloth towel to wipe he control panels.

ELECTRICAL

SHOCK

Do not use liquid or aerosol cleaners on the

laminator. Do not spill liquid of any kind on

the laminator. You can be severely shocked,

electrocuted or cause a fire. Use only a damp

cloth for cleaning unless other wise

specified.

Page 8 - 6

GBC Orca 1600 Operation And Maintenance Manual

Specifications and Main Features

Frequently Asked Questions

User Manual