GBC Orca 4064 Instruction Manual

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GBC Orca 4064WF-1 Wide

Format Professional

Solution Laminator

Instruction Manual

GBC 4064WF Operation Manual

GBC 4064WF

INSTALLATION & OPERATING MANUAL

Part Number: 930-132, Rev A.

ENG Operating Instructions

F Mode d'Emploi

Part Number: 930-132.Rev.10-17-05

E Instrucciones de Operación

GBC 4064WF Operation Manual

The information in this publication is provided for reference and is believed to be accurate and complete. General Binding Corporation (GBC) 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 reserves the right to make changes to this publication and to the products described in it without notice. All specifications and information con cerning 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 or others. GBC assumes no liability arising from infringements of patents or any other rights of third parties.

This publication is copyrighted © 2005 by GBC. 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.

ENG

L’information contenue dans cette publication est fournie à titre de référence et elle est considérée exacte et complète. General Binding Corporation (GBC) n’est pas responsable des erreurs contenues dans cette publication ni des dommages indirects ou consécutifs portant sur l’utilisation ou la p résentation de l’information de ce document, y compris, mais sans s’y limiter, toute garantie implicite de commercialité ou d’adaptation à un usage particulier.

GBC se réserve le droit d’apporter des modifications à cette publication et aux produits qui y sont décrits sans préavis. Toutes les spécifications et l’information au sujet des produits sont sujettes à changements sans préavis.

Toute référence à l’information ou aux produits protégés par un droit d’auteur ou un brevet présentée dans ce document ne porte aucune licence sous les droits de GBC ou d’autres parties. GBC n’assume aucune responsabilité découlant de contraventions aux brevets ou à tout autre droit de tierces parties.

Cette publication est protégée par un droit d’auteur © 2003 de GBC. Tous droits réservés L’information contenue dans cette publication est privative et ne peut pas être reproduite, mise en mémoire, transmise ou transférée, en partie ou en entier, sous quelque forme que ce soit sans la permission écrite préalable et expresse de GBC.

La información contenida en esta publicación es proporcionada a título de referencia y se considera que es precisa y completa. General Binding Corporation (GBC) no es responsable por errores contenidos en esta publicación o por daños consecuentes o incidentales r elacionados con la disponibilidad o el uso de la información en esta publicación, incluyendo y sin limitarse a, cualquier garantía de aptitud y comerciabilidad para cualquier uso específico.

GBC se reserva el derecho de hacer cambios en esta publicación y a los productos descritos en la misma sin aviso previo. Todas las características y la información referente a los productos, están sujetas a cambios sin aviso previo.

Las referencias en esta publicación a información o productos protegidos por derechos de propiedad intelectual o por patentes no otorga ninguna licencia amparada por los derechos de GBC u otros. GBC no asume ninguna responsabilidad que se derive de la violación de patentes u otros derechos de terceras partes.

Copyright © 2003 Esta publicación está amparada por derechos de propiedad intelectual de GBC. Todos los derechos reservados. La información contenida en este documento es de propiedad exclusiva y no puede reproducirse, almacenarse, transmitirse o transferirse, en su totalidad o en partes, y de ninguna manera, sin la autorización previa y por escrito de GBC.

GBC 4064WF Operation Manual

TABLE OF CONTENTS

Description Cover

Legal Disclaimer Table of Contents Important Safety Instructions Important Safeguards

General Electrical Service

Warranty Specifications Pre- Installation Installation Control Guide Power ON/OFF

Control Panel

LCD Display Display Reset Switch Display Main Switch (TOP Heater) Display Main Switch (Bottom Heater) Fan Switch Main Roller (Up / Down) Pull Roller (Up / Down) Laminator main Control Switch Machine Power On Light Laminator Directional Motion

Control Switch

Laminator Speed Control

Features Guide

E-Stop Buttons Nip roller Shim Dial Calibrating Disc Media tray table Swing out Film Unwind Shaft Unwind / Rewind Combo Upper Tension Idler Lower Tension Idler Rewind Take Up Removable Chill Idler Chill Idler Storage Area Heated Main Rollers Pull Rollers Pressure Plate Table Idler Main On / Off Switch Swing around Control Panel Arm Control Panel Box Nip Pressure Adjustment Electric Safety Beam

Page

No.

1 2 3 4 4

5 5 6 6 7 7

7 7 7 7 7 7 7 7 7 7

7 7 7

8 8 9

9 10 10 10 11 11 11 12 12 12 12 12 13 13 13 13

Description Sequence of Operations

Operating Instructions

Film Loading and Threading Load a Roll of Film Webbing Thermal Film using

Threading Card

Webbing PSA Film / Mount Adhesive

Using Threading Card Start Laminating Method for Tacking new Film to

Existing Film To Unweb The Laminator Clearing a Film Jam (Wrap–Up)

Applications

Pre-Coating Boards Mounting Pre-Coated Boards Single Sided Lamination Creating a Decal Thermal Encapsulation AccuShield™

Speed/Temperature Control

The Art of Lamination

Basic Rules Film Tension Heat Output

Maintenance

Trouble Shooting Guide

Service Agreement

Page

No.

15 15 16

17 18

19 20 20

21 21 21 21 22 22 22

24 24 24 25 25

GBC 4064WF Operation Manual

IMPORTANT SAFETY INSTRUCTIONS

YOUR SAFETY AS WELL AS THE SAFETY OF OTHERS IS IMPORTANT TO GBC. IN THIS INSTRUCTION MANU AL AND ON THE PROD UCT, YOU WILL FIND IMPORTANT SAFETY MESSAGES REGARDING THE PRODUCT. READ THESE MESSAGES CAREFULLY. READ ALL OF THE INSTRUCTIONS AND SAVE THESE INSTRUCTIONS FOR LATER USE.

THE SAFETY ALERT SYMBOL PRECEDES EACH SAFETY MESSAGE IN THIS INSTRUCTION MANUAL. THE SYMBOL INDICATES A POTENTIAL PERSONAL SAFETY HAZARD TO YOU OR OTHERS. THE FOLLOWING WARNINGS ARE FOUND UPON THIS PRODUCT.

ADVERTENCIA

Riesgo de choque eléctrico No abra: Adentro no hay piezas reparables por el usuario. Mantenimiento solamente por

personal calificado

Attention

Risque de Secousseélectrique. Ne pas ouvrir. Pas de pièces réparables par l'utilisateur. Entretien seulement par personnel qualifié.

THIS SAFETY MESSAGE MEANS THAT YOU COULD BE SERIOUSLY HURT OR KILLED IF YOU OPEN THE PRODUCT AND EXPOSE YOURSELF TO HAZARDOUS VOLTAGE.

ADVERTENCIA

RODILLOS CALIENTES. PUNTO DE PINCHAMIENTO. Mantener manos y ropa a distancia.

Attention

ROULEAUX CHAUDS. POINT DE PINCEMENT. Tenir mains et vêtements à l'écart.

THIS SAFETY MESSAGE MEANS THAT YOU COULD BE BURNED AND YOUR FINGERS COULD BE TRAPPED AND CRUSHED IN THE HOT ROLLERS. CLOTHING, JEWELRY AND LONG HAIR COULD BE CAUGHT IN THE ROLLERS AND PULL YOU INTO THEM.

ADVERTENCIA

NAVAJA FILOSA. Mantener manos y

dedos a distancia.

Attention

LAME COUPANTE.

Tenir mains et doigts à l'écart.

THIS SAFETY MESSAGE MEANS THAT YOU COULD CUT YOURSELF IF YOU ARE NOT CAREFUL.

WARNING: THIS SAFETY ALERT SYMBOL PRECEDES EACH SAFETY MESSAGE IN THIS INSTRUCTION MANUAL. THE SYMBOL INDICATES A POTENTAL PERSONAL SAFETY HAZARD TO YOU OR OTHERS.

WARNING: DO NOT ATTEMPT TO SERVICE OR REPAIR THE 4064 WF LAMINATOR.

WARNING: DO NOT CONNECT THE LAMINATOR TO AN ELECTRICAL SUPPLY OR ATTEMPT TO OPERATE THE LAMINATOR UNTIL YOU HAVE COMPLETELY READ THESE INSTRUCTIONS. MAINTAIN THESE INSTRUCTIONS IN A CONVENIENT LOCATION FOR FUTURE REFERENCE.

Electrical shock hazard. Do not open. No user serviceable parts inside. Refer servicing to qualified service

personnel.

Avertissement

HOT ROLLS. PINCH POINT.

Keep hands and clothing away.

Avertissement

SHARP BLADE. Keep hands and

clothing away.

Avertissement

IMPORTANT SAFEGUARDS

General:

Keep hands, long hair, loose clothing, and articles such as necklaces or ties away from the front of the heat and pull rollers to avoid entanglement and entrapment.

The heat rollers can reach temperatures over 300 Avoid contact with the heat rollers during operation or shortly after power has been removed from the laminator.

Keep hands and fingers away from the path of the sharp film cutter blade located at the film exit.

Do not use the laminator for other than its intended purpose. Avoid moving the Laminator on uneven floor surfaces. Never

tilt the laminator. Do not defeat or remove electrical and mechanical safety

equipment such as interlocks, shields and guards. Do not insert objects unsuitable for laminating or expose the

equipment to liquids.

Electrical:

The Laminator should be connected only to a source of power as indicated in these instructions and on the serial plate located on the rear of the laminator. Contact an electrician should the attachment plug provided with the Laminator not match the receptacles at your location.

Do not operate the Laminator with a damaged power supply cord or attachment plug, upon occurrence of a malfunction, or after the laminator has been damaged. Contact GBC’s Technical Service Department or your dealer/distributor for assistance.

Service:

Perform only the routine main tenance procedures referre d to in these instructions

Disconnect the plug from the receptacle and contact GBC’s Technical Department or your dealer/distributor when one or more of the following has occurred.

• The power supply cord or attachment plug is damaged.

• Liquid has been spilled into the laminator.

• The laminator is malfunctioning after being mishandled.

• The laminator does not operate as described in these

WARNING: TO GUARD AGAINST INJURY THE FOLLOWING SAFETY PRECAUTIONS MUST BE OBSERVED IN INSTALLATION AND USE OF THE LAMINATOR.

F (150oC).

WARNING: THE RECEPTACLE MUST BE LOCATED NEAR THE EQUIPMENT AND EASILY ACCESSIBLE.

WARNING: DO NOT ATTEMPT TO SERVICE OR REPAIR THE LAMINATOR

instructions.

GBC 4064WF Operation Manual

WARRANTY

Limited 90- Day Warranty

GBC warrants to the original purchaser for a period of ninety days on labor and one year on parts after installation that this laminator is free from defects in workmanship and material under normal use and service. GBC’s obligation under this limited warranty is limited to replacement or repair, at GBC’s option, of any part found defective by GBC without charge for material or labor.

THIS LIMITED WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED. WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY EXCLUDED. ANY REPRESENTATIONS OR PROM ISES INCONSISTENT WITH, OR IN ADDITION TO, THIS LIMITED WARRANTY ARE UNAUTHORIZED AND SHALL NOT BE BINDING UPON GBC. IN NO EVENT SHALL GBC BE LIABLE FOR ANY SPECIAL, INCIDENTAL, OR CONSEQUENTIAL DAMAGES, WHETHER OR NOT FO RESEEABLE.

SPECIFICATIONS

Operating Speed Up to 20 fpm (5.5 mpm) MAX Maximum Temperatur e 300oF (149oC) Maximum Mounting

Thickness Maximum Film Width 64 in. (162.5 cm) Dimensions (W x D x H) Unit alone: (Uncrated)

Weight Unit alone: 1500 lbs. (680 Kgs.).

Electrical Requirements Refer to the serial plate located on the rear of the laminator for the specif ic electrical rating applicable

Agency Approval cULus Voltage 220 V, 60 Hz Current 32 A Power 7000 W Phase Single FCC NOTE

1 in. (25.4 mm) Max.

86in. x 34.5in. x 57in. (218cm x 88cm x 145cm.)

Depth of 4064 WF is 44 in (112 cm) with tables in up position.

Shipping: 1700 lbs. (771 Kgs.).

to the unit.

FCC Class A Notice - Notification pour les Etats-Unis Note: This equipment has been tested and found to comply with the limits for a Class A digital

device, pursuant to part 15 of the FCC rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiated radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his own expense.

Canada Class A Notice - Avis Canada, Classe A

This Class A digital apparatus complies with Canadian ICES-003. Cet appareil numérique de la classe A est conforme à la norme NMB-003 du Canada.

Modifications

Any modifications made to th is device that are not approved by Genera l Binding Corporation may void the authority granted to the user by the FCC and/or by Industry Canada to operate this equipment.

Toutes modifications apportées à ce dispositif et non approuvées par General Binding Corporation annuleront le droit accordé à l'utilisateur par le FCC et/ou par Industrie Canada de faire fonctionner cet équipement.

This limited warranty shall be void if the laminator has been misused; mishandled; damaged by negligence, by accident, during shipment, or due to exposure to extreme conditions; repaired, altered, moved, or installed by anyone other than GBC or its authorized agents; or if incompatible film was used. GBC’s obligation under this limited warranty does not include routine maintenance, cleaning, adjustment, normal cosmetic or mechanical wear, or freight charges.

Without limiting the generality of the previous paragraph, GBC’s obligation under this limited warranty does not include:

1. Damage caused to the rollers by knives, razors, or other

sharp tools: by any foreign objects falling into the working area of the laminator; or by cleaning the laminator with solutions or materials that harm its surfaces;

2. Damage caused by adhesives; nor

3. Damage caused by lifting, tilting or attempting to position

the laminator other than rolling it on its castors across even surfaces.

FOR EUROPEAN UNION RESIDENTS ONLY: This guarantee does not affect the legal rights which consumers have under applicable national legislation governing the sale of consumer goods.

GBC 4064WF Operation Manual

PRE-INSTALLATION

INSTALLATION

1. Shipping damage should be brought to the immediate attention of the delivering carrier.

2. With assistance, carefully roll the laminator into position over flat and even surfaces.

3. The laminator should be positioned to allow exiting film to flow freely to the floor or a work table. Accumulation of

laminate immediately behind the laminator as it exits the equipment may cause the film to wrap around the pull rollers, resulting in a “jammed” condition.

4. Avoid locating the laminator near sources of heat or cold. Avoid locating the laminator in the direct path of forced,

heated or cooled air.

5. Once the laminator has been properly positioned, lock the castors in place. Locking the castors prevent the machine from

rolling during set up, operation or servicing.

6. Connect the attachment plug provided with the laminator to a suitably grounded outlet. Avoid connecting other

equipment to the same branch circuit to which the laminator is connected, as this may result in nuisance tripping of circuit breakers or blowing fuses.

Note: Machine must be leveled to ensure best performance. Level the machine by lowering both the main and pull rolls.

Lay A level on top of the main and pull rolls. Then, check level from main roll to pull roll on right and left side of the roll. Finally, check by placing the level diagonally across lower main to lower pull rolls.

Before a 4064 Laminator can be installed, ensure the following requirements are met:

1. Are doorways and hallways wide enough for the

laminator to be moved to the installation site?

2. 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.

3. Is the environment appropriate for the laminator?

• The laminator requires a clean, dust and vapor

free environment to operate properly.

• Avoid locating the laminator near sources of heat

or cold. Avoid locating the laminator in the direct path of forced, heated or cooled air.

CAUTION: Air flow can cause uneven heating / cooling of the rollers and result in poor output quality.

4. Have you contacted a certified electrician to wire the

receptacle and ensure that adequate power is being supplied, having the appropriate capacity, over current protection and safety lockouts available?

GBC 4064 WF Requires:

• 220V at 60Hz with 32 amps single.

• Nema 6-50 R 50 A 250 V Receptacle

This machine is supplied with a Nema 6-50 male plug

GBC 4064WF Operation Manual

CONTROL GUIDE

9 8

A. Power ON/OFF (I/O):

Located at the back left of the machine applies power to the laminator. The control panel display will illuminate when

osition marked “I” is pushed. The Off position, marked “O”

removes power from the laminator.

B. Control Panel (Figure 5)

1. LCD Display:

Displays-Time in minutes and seconds and material used in Feet (For North America), Meters (For All Other Areas)

2. Display Reset Switch:

Resets the LCD Display reading to zero.

3. Top Roll Display

• Displays Temperature in “

• LED Marked “

• LED Marked “Ready” illuminates when set temperature is

{a}. Control Switches

∧ - When pressed increases the Temperature ∨ When pressed decreases the Temperature

MEAS-Press and Hold to Display Current Bottom Roller Temperature.

4. Main Switch (TOP Heater): When pressed to the position turns On the top heater, when pressed to the position turns Off the top heater.

5. Bottom Roll Display

• Displays Temperature in “

• LED Marked “

• LED Marked “READY” illuminates when set temperature is

6. Main Switch (Bottom Heater): When pressed to the

osition turns On the bottom heater, when pressed to the

position turns Off the bottom heater.

7. Fan Switch: Switches cooling fan ON /OFF

8. Main Roller (Up/Down): ( ) Controls Up/Down

movement of Main Roller through pneumatics.

9. Pull Roller (Up/Down): ( ) Controls Up/Down movement of Pull Roller through pneumatics.

10. Machine Power On Light: Green light illuminatedMachine On.

11. Laminator Main Control Switch: Switches the laminator between “RUN” and “STOP” modes.

12. Laminator Direction Motion Control Switch: Controls the forward and rearward movement of the laminator.

13. Laminator Speed Control:

Regulates the speed of laminator feed.

• Outer Scale in Feet/Minute

• Inner Scale in M/Minute

(Both Set Temperature and Current Temperature, when MEAS switch is pressed).

C”, if Illuminated, indicates reading in “oC

“

reading in “

reached.

Heater. (Both Set Temperature and Current Temperature, when MEAS switch is pressed)

reading in “

reached.

F”, if Illuminated, indicates Temperature

F”

C”, if illuminated, indicates reading in “oC”.

F”, if Illuminated, indicates Temperature

F”.

C “or “oF” of the Top Heater

C” or “oF” of the Bottom

GBC 4064WF Operation Manual

FEATURES GUIDE

Refer to the following pages for detailed information on the above Features

FEATURES GUIDE (DETAILED DESCRIPTION)

Figure 1

A. Emergency Stop buttons: (Fig. 1 - Item A)

Four E-Stop buttons are on the laminator on the top

four corners of the Laminator. To engage E-Stop Button, press a ny E-Stop Safety

Push button to stop the roller movement To disengage turn the push button clockwise when

the emergency condition has been resolved B. Nip Roller Shim Dial: (Fig. 1-Item B)

Four NIP roller Shim dials are available on the laminator. One Pair on the front of the laminator is used for setting adjustment of the main roller.

One pair on the rear of the laminator is used for setting the adjustment of the pull roller & main rolls. C. Nip Roller Shim Indicator: (Fig. 1-Item C) Four NIP Roller Shim Indicators are on the laminator. NIP Roller Shim Indicators are used to indicate adjustment of the pull roller.

GBC 4064WF Operation Manual

Figure 2

Figure 3-1

Figure 3-2

To use the NIP Roller Shim Dial:

Raise the Rollers (Main Hot Roller, Pull Roller or both) using the Main Roller (Up and Down) or Pull Roller (Up and Down) Switch on the Control Panel.

Adjust the Roller Heights to the desired Setting with the nip roller Shim dial and Lower the Upper Roller back down to the Laminating Position.

Note:

The NIP Roller Shim dials should be used in Pairs for Adjustment settings of the desired Rollers

Do not use the adjustments independently. The left and right side of shim setting for each roll must be at the same setting.

Media Tables: (Fig. 2A)

On both the front media and rear media tables, the safety interlock switch will not allow the laminator to operate at full speed unless the tables are properly installed.

The Media tables are used to Position items for Lamination. There are Two Media Tables on the machine, one on the front & one on the rear of the Laminator. Media tables incorporate an Idler on the leading edge of the table. This is used for Roll to Roll applications during lamination

Note:

The Laminator will operate only when the Media Table and Media Table Latches are Properly Installed.

The Accessories Include:

1. Straight Slitter - Used for Slitting the Media after lamination -Rear Table. (Fig. 2B)

2. Feed Guide - Used for guiding Media through the laminator. (Fig. 5B)

3. Pressure Plate - Used for guiding stock and ensuring a wrinkleless feed into the roller Front table. (Fig. 10A)

Swing out Film Unwind Shafts: (Fig. 3-1B, 4A & 5A)

The Swing out film un wind shaft is used to provide tension to materials going into the lamination rollers. There are three swing out film unwind shafts present on the machine, two are located on top of the machine, and the other one is located below the front table. (Fig. 3-1 Item B)

Lower Tension Idler: (Fig. 3-2 Item A)

Lower tension idler guides the lower lamination film onto the lower rollers.

GBC 4064WF Operation Manual

Unwind / Rewind Combo Shafts: (Fig. 3)

Figure 4

A B

Figure 5

There are two lower combo unwind / rewind shafts, one on the lower front and one on the lower back of the machine.

Unwind/rewind combo shafts can be used as standard swing out unwind shafts for material supply or be used as rewind shafts for liners and final products.

The conversion from unwind to rewind just requires the release of the brake adjust knob (Fig. 3E) and tightening the rewind adjustment knob (Fig. 3F).

Note: When using the combo unwind / rewind shaft as a rewind. The brake tension knob must be released to limit the load on the motor, and wear & tear on the machine.

The film shaft clutch is then engaged to turn with the motor to wind up the film.

Upper Tension Idler: (Fig. 4 – Item B)

Upper tension I dler guides the laminating film onto the main roll insuring a consistent amount of wrap on the upper rolls.

GBC 4064WF Operation Manual

Rewind Take up tubes: (Fig. 6 – Item A)

This machine has three dedicated rewind film take up tube position s. Only one of them is shown in Fig. 6.

Figure 6

Figure 7

Figure 8

Two rewind tubes are on top front and back and one rewind tube is on the lower back side of laminator.

Removable Chill Idler: (Fig. 7 – Item A)

The removable chill Idler is used to help smooth out the laminating film during the cooling process.

Chill Idler Storage Area: (Fig. 8 - Item A)

Chill Idler can be stored in the lower brackets when the machine is set up for board mounting.

GBC 4064WF Operation Manual

Heated Main Rollers: (Fig. 9 – Item A)

Silicone rubber coated steel tubes heat the

Figure 9

Figure 10

laminating film and compresses the heated film to the items being laminated. Heat is provided by an internal heating element.

Pull Rollers: (Fig. 9 - Item B)

The Pull Rollers located at the back of the laminator are motor driven. They simultaneously pull the film and improve the quality of the lamination.

Pressure Plate: (Fig. 10 – Item A)

The Pressure Plate mounted to the front of the table helps hold down the image as it enters the Nip Area.

Table Idler: (Fig. 10 – Item B)

The Table Idler is used to assist in bringing the material up to the nip.

The table Idler is helpful in roll to roll operation and helps move large ridged panels through the nip.

Main On / Off (I/O) Switch:

(Fig. 11 – Item A)

Located on the lower back of the control panel side of the GBC4064WF is the main power switch. “I” means ON, “O” means OFF

Figure 11

GBC 4064WF Operation Manual

Figure 12

Figure 13

Figure 14

Swing around control panel arm:

(Fig. 12 – Item A)

The Control panel is on a swing around arm which will allow the operator to move the necessary control to each side of the machine.

Control Panel: (Fig. 12 – Item B)

The Control panel has most the machine controls to operate the machine.

Nip Pressure Adjustment:

(Fig. 13 – Item A)

The Nip pressure adjustment is a pneumatic air regulator and a gauge that allows the operator to adjust the downward pressure of the pull rolls and main rolls.

Electronic Safety Beam: (Fig.14-Item A and Fig. 15–Item A)

Safety light beam is used to protect the Nip area with out being in the way of normal lamination operation. Please see the following chart for sequence of operations:

Figure 15

GBC 4064WF Operation Manual

SEQUENCE OF OPERATIONS

GBC U.S &CE 4064WF

Effect of Fiber Optics on sequence of operation

Modes Situation 1 Situation 2 Situation 3

Machine Run Mode

Normal operation (No Interruption to any

safety circuitry & Fiber optic beam)

High speed.

Interrupted fiber optic beam or opened any safety circuitry.

Fiber optic beam cleared + all safety circuitries are closed

Forward Mode

Press push button forward switch

Reverse Mode

Press Reverse Push button switch.

Control panel:

Forward Speed: Zero to Max.

Press “Run” push button to switch over from foot switch to the control panel.

Foot switch:

Forward Speed: Zero to Max.

Note: Press variable

foot pedal to change mode and take over from control panel at preset speed.

Reverse speed: Zero to Max.

Press “Run” push button to switch over from Foot switch to the Control panel.

Reverse speed: Zero to Max.

Note: Press foot pedal

to change mode and take over from control panel.

Machine stops Instantly.

Use foot pedal to override @ 3f/m.

Machine Runs @ 3f/m.

(Automatic override from high to low voltage)

Machine stops Instantly.

Use Foot pedal to override @ 3f/m.

Machine Runs @ 3f/m. (Automatic override from high to low voltage)

Machine will remain stationary until run switch is pressed.

Push RUN button switch to run machine again (Normal operation) mode.

Machine still remains at low voltage speed of 3f/m.

Steps required to run at (various speed): The operator will have two choices,

Choice A:

1. Release foot pedal to stop machine.

2. Press foot pedal again to start

machine at original preset control panel knob speed (pot).

Choice B:

1. Press and hold “Run” push button

switch on the control panel w h ile foot is still on pedal.

2. Release foot pedal.

3. Adjust speed using “speed knob”

Machine must not run. It will remain stationary. Push RUN button switch to run machine again at Normal operation mode.

Machine still remains at low voltage speed of 3f/m.

Steps required to run at (various speed): The operator will have two choices,

Choice A:

1. Release foot pedal to stop machine.

2. Press foot pedal again to start

machine at original preset control panel knob speed (pot).

Choice B:

1. Press and hold “Run” push button

switch on the control panel w h ile foot is still on pedal.

2. Release foot pedal.

3. Adjust speed using “speed knob”

GBC 4064WF Operation Manual

OPERATING INSTRUCTIONS

Film Loading & Threading

The top and bottom rolls of laminating film must be of the same width and be present simultaneously. A Small amount of adhesive will “squeeze out” during Lamination. Hardened adhesive deposits can damage the heat rollers.

CAUTION:

Adhesive will deposit on the rollers if:

• Only one roll is used.

• Different widths of rolls are loaded together.

• Either roll is loaded adhesive side against a heat roller.

• One or both rolls of film are allowed to run completely

off its core.

The adhesive side of the film is on the inner side of the web (Fig. 16 A and B). The shiny side of clear film must contact the heat rollers. The dull side of the film contains the adhesive. Use extreme caution when loading delustered (matte) film as both sides appear dull.

Always change the top and bottom supply rolls at the same time. Near the end of each roll of GBC laminating film is a label stating “Warning-End of Roll”. The appearance of this label on either the top or bottom roll requires that new rolls of film be installed as soon as the item presently being laminated completely exits the rear of the laminator.

Do not introduce any additional items into the laminator when the warning label is visible.

To load a roll of film:

(Fig. 17)

1. Pull the swing out shaft clevis pin up.

2. Swing shaft outward.

3. Slide the roll of film onto the film shaft ensuring

Adhesive side is out.

4. Push the film shaft back into the film shaft Support

saddle.

5. Push the clevis pin down.

6. Center the roll of film.

Polyester surface

Figure 16

Figure 17

6 =

GBC 4064WF Operation Manual

Webbing Thermal Film Using Threading Card

CAUTION: The laminator rollers will be ho t and

can burn you.

1. Turn the Main Power ON /OFF to On.

2. Set top and bottom temperatures to the appropriate

setting for th e film type used.

3. Ensure no brake tension is applied to the film shafts.

4. Pull the top roll film down under the upper idler bar

and allow to drape over the top heat roller (Fig. 19)

5. Pull the lower film behind the lower idler bar, Lower

the table, Pull Film up towards the film draped over the top heat roller and adhere the lower film to the upper film (Fig. 20).

6. Pivot the table back to its feeding position while

ensuring the threading card is on top of the feed table (Fig. 21).

7. Use a threading card to push the two materials into

the heat roller nip.

8. Lower the main roller to initial contact with the

threading card.

9. Ensure FRONT is selected for Motor direction and

Press the Foot Switch

10. From the rear of the machine, guide the web over the

chill idler, if installed, and through the pull rollers.

11. Once the web has entered the pull roller nip, lower

the pull roller. Adjust unwind film tension; use as little tension as possible to get smooth output. (See Page.9).

12. Once the threading card has completely exited the

pull rollers, press the “STOP” ( ) button.

13. Now refer to the section titled “START

LAMINATING”.

Thermal

Laminate

Figure 19

Figure 20

Thermal Laminate

Thermal

Laminate

Figure 21

GBC 4064WF Operation Manual

Webbing PSA Film/Mount Adhesive Using Threading Card

The laminator should be cool to the touch before Proceeding.

1. Turn the Power ON /OFF to On

2. Load the rolls of film as illustrated in (Fig. 22).

Ensure no brake tension is applied to the film shafts.

3. Pull the top roll of film down under the idler bar

and up to the upper front rewind tube.

4. Place one piece of masking tape in the center of

the film and secure to the rewind tube.

Figure 22

REWIND TUBE

Figure 23

REWIND TUBE

5. Make two full wraps around the rewind tube,

and then score the laminate without cutting the release liner. Pull th e lamina te down al lowing it to drape over the upper roller (Fig. 22).

6. Pull the mount adhesive up towards the film

draped over the upper heat roller (Fig. 23).

7. Stick the mount adhesive to the exposed

adhesive of the upper role.

8. Pivot the table back to its feeding position while

ensuring the threading card is on top of the feed table (Fig. 24).

9. Use a threading card to push the two materials

through the heat roller nip

10. Lower the main heated roller to bring the main

roller into initial contact with the threading card. Ensure front is selected and press the foot switch.

11. From the rear of the machine, guide the web

over the chill idler, if installed, and through the pull rollers. Once the web has entered the pull roller nip, close the pull roller nip.

12. Press the “STOP” ( ) button when the

threading card has completely exited the pull rollers and adjusts the film web tension using as little tension as possible.

13. Now refer to the section titled “START

LAMINATING”.

CHILLED ROLLER

HEAT ROLLER

Figure 24

GBC 4064WF Operation Manual

Start Laminating

1. At this point you should have your laminator Webbed

with the appropriate material for your application.

2. The feed table should be in the normal operating

position.

3. Close the main and Pull roll nips. Rollers should be

closed.

4. Speed is set to 3 or less and “FRONT” ( ) motor

direction is selected.

5. Press the “START” ( ) button.

6. Set main roller pressure between 0.4 – 0.6 MPa for

laminating by turning the NIP prices via adjustment

CAUTION: If using PSA film, an air pocket may result between the main rollers and pull rollers. Raise the pull rollers to allow the air Pocket to pass.

7. Make any necessary film brake tension adjustments,

pull/main roller pressure, and clutch and/ or rewind brake tension adjustments.

8. Position the item to be laminated on the feed table.

9. Align the leading edge of the item parallel to the heat

roller nip (Fig. 25).

10. With both hands and an outward force push the image

slower than the sp eed of the roll ers into t he nip of the heat rollers (Fig. 26).

CAUTION: Avoid forcing the image into the main roller nip as this action will cause the corners of the leading edge to buckle and create a wave.

Figure 25

Figure 26

GBC 4064WF Operation Manual

Method for Tacking New Film to Existing Film

The following d escribes a me thod for loading film whereby the existing film present on the heat rollers may be used in place of the threading card to draw the new film through the laminator. The adhesive of the existing film must be tacky or liquefied. Leading edges of the new film will be overlapped onto the tacky adhesive of the old film. The existing film and the new film will be pulled through the laminator together.

CAUTION: Do not cut yourself

CAUTION: Be careful not to cut any of the rollers!

1. Cut (1) remaining top film web between the

idler bar and heat roller. Cut (2) the film web between the lower film supply and the idler bar (Fig. 27).

2. Tilt the feed table down.

3. Do not allow the adhesive side of the film to

contact the heat or pull rollers. Liquefied or tacky adhesive deposited on heat rollers will require the rollers to be cleaned per the section tilted “MAINTENANCE”.

4. Replace both the top and bottom rolls of film

with new rolls. Ensure the adhesive side is facing out.

5. Pull the film around the idler bars, with the

exception of PSA moun ting adhe sives without a release liner.

6. Tack the new film to the existing film on the

heat rollers. For PSA film, attach the release liner to the rewind tube

7. Use the footswitch to advance the film into the

heat roller nip.

8. Observe the film being pulled through the

laminator to assure that the remaining existing film and the new films are advancing concurrently. Any separation between the films will require stopping the motor immediately and the situation corrected.

9. Press “STOP” ( ) once the newly threaded

film has completely exited the p ull rollers.

= PSA fil m or mount adhesiv e

= PSA film or mount adhesive

(1)

(2)

Figure 27

GBC 4064WF Operation Manual

To unweb the laminator

Unweb the laminator if you are changing film widths, cleaning the rollers or have finished using the machine for the day.

CAUTION: Do not cut yourself

1. Using the rear slitter, cut (1) the output from the

web (Fig. 28).

2. Cut (2) remaining top film web between the

idler bar and heat roller. PSA film cut the release liner too.

3. Cut (3) the film web between the lower film

supply and the idler bar (Fig. 28).

CAUTION: Be careful not to cut any of the rollers!

4. Tilt the feed table.

5. Gap the main rollers and pull rollers.

6. Carefully grab hold of the web (top and bottom

film), from the back operating position and pull towards you (Fig. 29).

7. Do not allow the adhesive side of the film to

contact the heat or pull rollers.

Clearing a Film Jam (Wrap-up)

Film jams (wrap-ups) may occur if the film is loaded backwards or if the area at which film exits the equipment is blocked. The film, when jammed, wraps around the heat rollers or pulls rollers during webbing if webbing, if a Threading Card is not used.

To clear a jam:

1. Immediately stop the laminator by pressing

“STOP” ( ).

2. Set motor direction to “REAR” (. ).

3. Use the footswitch to reverse the web until the

wrap up is clear.

4. Raise the main rol l er and pull rollers.

5. Manually guide the web from the main rollers

and pull rollers.

6. Once the film jam has been cleared, lower the

main roller and pull rollers.

7. Refer to the section titled “START

LAMINATING”.

(2)

(1)

(3)

(2)

= PSA film or mount adhesive

Figure 28

Pull web

Figure 29

GBC 4064WF Operation Manual

APPLICATIONS

Tips for Pre Coating Boards

1. Load the laminator as illustrated in (Fig. 30).

Remove chill idler.

2. The width of the roll should not exceed the

width of the board by more than 1/2 in. (1.3 cm).

3. Use a leader board to set the main roller and

pull roller pressure prior to webbing.

4. Use a leader board to start the run and a trailer

board to finish the run.

5. Using the pull rollers will allow you to leave

gaps between boards.

6. If not using the pull rollers, have the boards

nearby to butt end to end during feeding.

Tips for Mounting Pre Coated Boards

1. Use a leader board to set the main roller

pressure prior to mounting the image.

2. Ensure the chill idler is removed and the rear

slitter is to one side.

3. Do not stop once you have started the mounting

process through the machine. (Fig. 31)

Note: This application can also be performed from the rear operating position. Reference Fig. 34 for Illustration.

Tips for Single Sided lamination

1. Load the laminator as illustrated in Fig. 32.

2. Use kraft paper for one-sided lamination When

ever the items to be laminated are narrower than the film you are using.

3. If not using kraft paper, use a scrap piece to

finish the run or you will have adhesive on your rollers.

4. For high volume runs, use Kraft paper and the

lower rear rewind for roll to roll operation.

5. Running the web over the chill idler may

improve the Flatness of the output.

6. A little heat, 125

silvering effects associated with PSA films.

F (52oC), may help eliminate

Image

Release liner

Pre-coated baord

RELEASE LINER FROM PSA FILM

IMA G E

KRAFT PAPER OPTION

Figure 30

Figure 31

Figure 32

MOUNT

ADHESIVE

Mount

Adhesive

Boards

Leader boardTrailer board

OUTPUT

ROLL TO ROLL OPTION

GBC 4064WF Operation Manual

Tips For Creating a Decal

THERMAL

FILM

Thermal

or PSA

Film

IMAGE

RELEASE LINER

OUTPUT

ROLL TO ROLL OPTION

Output

Roll to roll option

BOARD

1. Load the laminator a s illustrated in Fig. 33.

2. The over laminate may be PSA or thermal type.

3. If using thermal type, pay attention to the Poly-

in/Poly-out rule.

4. Run a test material prior to running the actual

image to ensure flat output.

5. Use minimal brake tension to achieve quality

output.

6. Do not web the PSA mount adhesive around the

lower web idler.

Tips for mounting a Decal

1. Use a leader board to set the pull roller pressure

prior to mounting the image. (Fig. 34)

2. The image should not exceed the width of the

board by more than 1 in. (2.54 cm) per side.

3. Tack about 1 in. (2.54 cm) of the leading edge

of the image to the leading edge of the board.

4. When tacking the leading edge, start in the

center and work to the sides.

5. Use a board that exceeds the size of the decal if

inexperienced in the mounting application.

Note: This application can also be performed from the front operating position. Reference Fig. 31 for Illustration.

Tips for Thermal Encapsulation

1. Load the laminator as illustrated in Fig. 35

Poly-in film is used for illustration purpose.

2. Refer to section titled “FILM LOADING &

THREADING” for Poly-out film.

3. Always use two rolls of film the same width.

4. Use minimal brake tension to achieve flat

output.

5. Increase speed gradually to maintain the

activating temperature required for the laminate you are using.

6. Length and width of image, ink coverage and

paper type may effect the temperature and speed recommended in the SPEED/ TEMPERATURE GUIDE.

Release liner from PSA film

Image

IMAG E

Mount

Adhesive

THERMAL

FILM

Figure 33

Figure 34

Figure 35

GBC 4064WF Operation Manual

Tips for ACCUSHIELD

1. Load the laminator as illustrated in Fig. 36.

2. You must have the Separator bar option to

accurately run this material.

3. Set Top Temp to 265

F (129oC) and a speed setting

no greater than 4.

4. Liner rewind tension will be greater than normal

operating standard

5. To prevent some adhesive adhering to the rollers,

you may choose to use a roll of craft paper for a Carrier.

Use the blank space below and blank diagrams to Note your tips and web paths for your Special

applications.

TIPS FOR CUSTOM APPLICATION #1 (Fig. 37)

TIPS FOR CUSTOM APPLICATION #2 (Fig. 38)

IMAGE

KRAFT PAPER OPTION

THERMAL

FILM

Figure 36

Figure 37

REWIND

OPTIONAL SEPERATOR BAR

ROLL TO ROLL OPTION

Custom Web Path #1

OUTPUT

Custom Web Path #2

Figure 38

GBC 4064WF Operation Manual

SPEED / TEMPERATURE CONTROL

This is only a general reference guide. Different settings may be s uita ble as the warm up time, lamination time and materials change.

Factors that may affect the speed and temperature parameters;

1. Image length thickness

2. Image width and ink coverage

3. Ink coverage

4. Paper type

5. Laminate thickness

6. Operating environment

7. Condition of the rollers

8. Line voltage (effects heaters)

9. Using cooling features.

You may have to adjust temperature or speed depending on stock finish, *Turn heat off when not in use.

NIP ROLLERS SHIM DIAL Adjustment

The Nip Setting dail has the following choices.

“LAM”, 0”, 1/16

The “LAM” Setting is used in applications where full pressure is desired. The “LAM” is used for some applications like P ressure se nsitive or encapsulation where thick material is being laminated and better edge seal is needed.

The “0” setting is used in most general encapsulation applications, especially when laminating wide thin materials.

The “0” setting provides a positive stop on the downward pressure regardle ss of the Pneumatic downward pressure. The positive Stop helps to create the most consistent even Nip foot print across the roll.

The “O” setting is adjusted and set with the Main rolls cold, a small amount of light is visible between the rolls about 5” in from each end.

THE ART OF LAMINATION

BASIC RULES

• Do not attempt to laminate abrasive or metal Objects such as staples, paper clips and glitter, as they may damag e the heat or pull rollers.

• Do not force items into the nip area of the heat rollers. An item that is not easily drawn into the laminator by the heat rollers is probably

• Wrinkles may result if an attempt is made to reposition an item once it has been grasped by the heat rollers.

• Do not stop the laminator before an item has completely exited the pull rollers. Even a momentary stop will cause a mark (heat line) on

Good, consistent lamination is a result of combining proper heat, tension and dwell time. Dwell time is controlled by the speed of the motor and is defined as the amount of time the material to be laminated is compressed between the hea t rollers.

As a general rule, thi cker items and fil m need to r un at slow er speeds b ecause t hey extr act mor e heat fro m the roll ers at a qui cker rate. Setting the speed control at slower settings gives the laminator longer dwell time thus allowing proper lamination of thick items. Thinner items, such as standard copier paper (20 lb. bond) and tissue paper, extract less heat from the rollers and can be run at faster speeds.

FILM TENSION

Proper film tension, known as brake tension, is the minimum amount required to eliminate wrinkles in the finished item. The film should be taut. A properly adjusted roll of film should not require excessive force to turn by hand.

Film tension should be enough to introduce a minor amount of drag as the film unrolls. Insufficient tension causes wrinkles, while too much tension causes stretching (necking). Uneven tension between the top and bottom rolls creates curl. Too much upper tension creates upward curl while too much bottom tension causes downward curl.

Adjustment of the pull roller clutch may be necessary if after adjusting unwind and rewind brake tensions do not improve your output quality.

”, 1/8th”, 3 /16th“, 1/4th”, 3/8th”, 1/2th”, 3/4th” & 1”

too thick to laminate.

the laminated item.

GBC 4064WF Operation Manual

Heat

The “READY” indicator may extinguish if the speed is set too fast for the material being laminated. Either lower the speed setting or press “STOP” ( ) and wait until the “READY” indicator illuminates. Operation of the laminator for more than thirty minutes at a time may necessitate a lower speed setting. It is recommended that, during periods of long runs, the items being laminated are alternated between thick and thin. Do not combine thick and thin items at the same time, as this will result in a poor edge seal around the thinner material. If you are unsure that the laminator is set at the proper speed for the item to be laminated, run a test piece (scrap) of the same or similar material through the Laminator. This procedure is

- A - - B -

Figure 39

- A - - B -

Figure 40

recommended because rotating the heat roller prior to lamination will more evenly distribute the heat.

Make speed adjustments if necessary.

Output

1. “D” waves in the image (Fig. 39 A).

• Check paper tension.

• Paper may be damp or not dry.

2. “D” waves in the laminate (Fig. 39 B).

• Ch eck main roller pressure.

• Check pull roller pressure.

3. Straight waves in output (Fig. 40 A).

• Check operational settings for materials being

used.

• Check clutch tension.

4. Indent waves in output after pull rollers (Fig. 40 B)

• I nsufficient cooling time.

• Output was handled prior to cooling.

• Use cooling feature if not on.

• Machine was stopped on print.

5. Angled waves in the output (Fig. 41A & B)

• Main air Supply setting

• Check main Roller Pressure.

• Check pull roller pressure.

• Check for Paper Tension.

- A - - B -

Figure 41

GBC 4064WF Operation Manual

MAINTENANCE

Caring For the GBC 4064WF Laminator

GBC offers Cleaning kits as well as Extended Maintenance Agreements. Contact your local GBC Service Representative or your dealer/distributor for additional information. The only maintenance required by the

operator is to periodically clean the heat rollers and schedule semi annual maintenance checks. The following procedure will help keep the heat rollers free of adhesive that has been deposited along the edge of the

laminating film. Proper alignment of the rolls of film reduces the amount of “squeez e out”.

WARNING: Do not attempt to laminate adhesives marked “Flammable”. Do not laminate glitter and/ or metallic items. Damage to the rollers may result.

WARNING: Do not apply any cleanin g flu ids or solvents to the rollers. Some solvents and fluids could ignite on heated rollers.

Never clean rollers with sharp or pointed objects. Hardened adhesive depo sits on t he rollers can cause da mage to the ro llers. Rot ate the rol lers at the lo west spee d

setting on the control panel.

CAUTION: THE FOLLOWING PROCEDURE IS PERF ORMED WHILE THE LAMINATOR IS HOT. USE EXTREME CAUTION.

1. Remove the film from the laminator following the Procedure outlined in steps 1 through 6 of the section titled “TO UNWEB THE

LAMINATOR”.

2. Preheat the laminator until the “READY” indicator Illuminates.

3. Tilt the feed table.

4. Rub the top and bottom heat rollers with a 3M™ Scotch-Brite™ pad . DO NOT USE METAL SCOURING PADS!

5. Use the footswitch to rotate the lower heat/ pull roller to an unclean portion. The upper heat/ pull rollers are free spinning. Continue this

process until the complete surfaces of both rollers are clea n.

6. Refer to the beginning of the section titled “OPERATING INSTRUCTIONS” to web your laminator.

NOTE: Do not use metal scouring pads to clean the rollers.

GBC 4064WF Operation Manual

TROUBLE SHOOTING GUIDE

SYMPTOM POSSIBLE CAUSE CORRECTIVE ACTION

illuminate when POWER ON/OFF is in the ON, marked “I”, position Heat rollers do not turn when POWER ON/OFF is in the ON,

Laminator not connected to electrical supply Blown out fuse. Check fuses. Feed table not properly installed. Tilt feed table and properly replace

Insert attachment plug into receptacle The control panel display does not

it. marked “I”, position. Press the RUN ( ) button and the motor does not run Heat rollers only turn if I use the “Footswitch”. Laminated items exhibit curling.

E-Stop button activated Pull out on the E-STOP turn

clockwise.

Photo eye is blocked. Disengage the footswitch mode.

Clear nip area.

Tension between the top and bottom film. Roll is unequal. Tension on top or bottom roll of film is too film is too loose. Bottom film roll may be improperly loaded.

Adjust tension per section FILM

TENSION.

Adjust tension per section FILM

TENSION.

Make sure bottom roll of film is

around idler bar and that is the

normal operation position. Adhesive deposited on heat roller s.

Top and bottom film webs not aligned

Release heat and pull roller pressure,

align the rolls of film.

Laminate improperly loaded. Adhesive (matte) side of laminate

film may be against the heat rollers.

Unweb and reload the film properly. Unsatisfactory adhesion of laminate.

Speed setting too fast for type of

Lower speed setting.

material being laminated Insufficient heat Wait for “READY” indicator to

appear in the control panel display.

Laminate improperly loaded Adhesive side of film must be facing

away from the heat rollers.

Heat rollers require cleaning. Bottom roll of fi lm not threaded

behind the idle bar.

Laminated item unsuitable for adhesion.

Clean heat rollers per procedure in

section CARING FOR THE GBC

4064 WF LAMINATOR. Item may

be dirty or may have non porous

surface that is extremely difficult to

laminate.

SERVICE AGREEMENT

GBC’s Equipment Maintenance Agreement will insure the quality performance and long li fe built into your laminator. A service charge for travel time, labor and parts may be incurred for each out of warranty service call. GBC’s Equipment Maintenance Agreement decreases these expenses and protects your valuable investment. GBC offers several types of agreements to suit your needs and budget. To contact

GBC write to:

GBC NATIONAL SERVICE IN CANADA: GBC NATIONAL SERVICE ONE GBC PLAZA 49 RAILSIDE ROAD NORTHBROOK, IL 60062 U.S.A. DON MILLS, ONTARIO M3A 1B3

General Binding Corporation One GBC Plaza Northbrook, IL 60062-4195 ®

GBC Orca 4064 Instruction Manual

Specifications and Main Features

Frequently Asked Questions

User Manual