GBC ORCA III, ORCA III T Operation & Maintenance Manual

ORCA III/ ORCA III T

OPERATION & MAINTENANCE

MANUAL

© February 2001 GBC Films Group

Do not duplicate without written permission.

III T

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Pro - Tech

GBC

Pro - Tech

GBC

GBC Pro - T ech

4151 Anderson Road

DeForest, WI 53532
Revision : Ph: ( 608 ) 246 - 8844
Part number : 930 - 062

Fx: ( 608 ) 246 - 8645

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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,
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© GBC Films Group February 2001

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

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

T able of ContentsOrca III/ Orca III T Operation and Maintenance Manual

Table of Contents

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

Section 2.0 Warranty

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

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

© GBC Films Group February 2001

Page I

T able of Contents Orca III/ Orca III T Operation and Maintenance Manual

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

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

4.4 Shrink wrapped .........................................................................................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

Page II

© GBC Films Group February 2001

4.11 Unwind/ rewind brake .............................................................................4 - 14

4.12 Slitter assemblies .....................................................................................4 - 15

4.13 Calibrations .............................................................................................4 - 16

Section 5.0 Operations

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

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

T able of ContentsOrca III/ Orca III T Operation and Maintenance Manual

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

5.3 Rear control panel ......................................................................................5 - 6

Figure 5.3.1 Rear control panel ............................................................5 - 9

5.4 Setting temperature ...................................................................................5 - 10

5.5 In case of an emergency ...........................................................................5 - 11

5.6 Film loading/ unloading ...........................................................................5 - 12

5.7 Main roller nip ..........................................................................................5 - 14

5.8 Pull roller nip ............................................................................................5 - 14

5.9 Unwind brake tension ...............................................................................5 - 15

5.10 Rewind brake tension .............................................................................5 - 15

5.11 Shutdown procedure ................................................................................5 - 16

© GBC Films Group February 2001

Page III

T able of Contents Orca III/ Orca III T Operation and Maintenance Manual

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

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

Figure 6.4.1 Poly in/ Poly out 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 ( Roll to roll psa decaling ) .....................................................6 - 12

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

Chart - 4 ( Mounting a PSA decal - Main rollers ) ................................6 - 14

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

Chart - 5 ( Mounting a PSA decal - Pull rollers ) ..................................6 - 16

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

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

Page IV

© GBC Films Group February 2001

T able of ContentsOrca III/ Orca III T Operation and Maintenance Manual

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

Chart - 7 ( Thermal encapsulation ) ......................................................6 - 20

Diagram - 7 ............................................................................................6 - 21

Chart - 8 ( Roll to roll thermal encapsulation ) .....................................6 - 22

Diagram - 8 ............................................................................................6 - 23

Chart - 9 ( PSA encapsulation - Main rollers ) ......................................6 - 24

Diagram - 9 ............................................................................................6 - 25

Chart - 10 ( Roll to roll PSA encapsulation ) ........................................6 - 26

Diagram - 10 ..........................................................................................6 - 27

Chart - 11 ( PSA encapsulation - Pull rollers ) ......................................6 - 28

Diagram - 11 ..........................................................................................6 - 29

Chart - 12 ( Vinyl transfer with trimming ) ...........................................6 - 30

Diagram - 12 ..........................................................................................6 - 31

Chart - 13 ( Vinyl transfer no trimming ) ..............................................6 - 32

Diagram - 13 ..........................................................................................6 - 33

Chart - 14 ( Over-lamination of transferred vinyl images ) ..................6 - 34

Diagram - 14 ..........................................................................................6 - 35

Chart - 15 ( Roll to roll vinyl transfer ) .................................................6 - 36

Diagram - 15 ..........................................................................................6 - 37

© GBC Films Group February 2001

Page V

Table of Contents Orca III/ Orca III T Operation and Maintenance Manual

Section 7.0 Troubleshooting

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

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

7.2.1 Thermal laminates ........................................................................7 - 3

7.2.2 Pressure sensitive .........................................................................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

8.8 Chain tensioning .........................................................................................8 - 6

8.9 Lubrication .................................................................................................8 - 7

Figure 8.9.1 Grease fitting points ...........................................................8 - 9

Page VI

© GBC Films Group February 2001

1.0 Safety

CAUTIO N

Do n o t attempt to o p era te y ou r O r ca III/

Orca III T laminator until you have read

this s ec tio n c a re fully!

SafetyOrca III/ Orca III T 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.

© GBC Films Group February 2001

ELECTRICAL

SHOCK

Indicates an electrical shock situation which,

if not avoided, could result in serious

paralyzation of the body or death.

Page 1 - 1

Safety Orca III/ Orca III T Operation and Maintenance Manual

1.2 Pneumatic safety

The Orca III/ Orca III T 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.

CAUTION

1.3 Safety features

Important safety features of the Orca III/ Orca

III T 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.

E

M

E

R

G

Engaged

Push

E

N

P

O

T

S

Y

C

E

Turn

E

M

R

G

E

C

N

Disengaged

P

O

T

S

Y

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.

Page 1 - 2

© GBC Films Group February 2001

SafetyOrca III/ Orca III T 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 III/ Orca III T 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

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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 )

Front pull roller

photo-eye

( 3 )

Rear pull roller photo-eye

( 1 )

Main roller

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.

© GBC Films Group February 2001

Page 1 - 3

Safety Orca III/ Orca III T 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 III/ Orca

III T 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.

CAUTION

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.

Page 1 - 4

© GBC Films Group February 2001

SafetyOrca III/ Orca III T 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.

CAUTION

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

© GBC Films Group February 2001

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 1 - 5

Safety Orca III/ Orca III T Operation and Maintenance Manual

WARNING

Th e Orca III/ Orca III T Lam in ator is a

large and h eav y p iece of eq u ipm en t. It is

necessary to employ L IC E N S E D RIGG E R S

O N LY to move th e la mina tor . It is n ot

designed to be tipped up or sideways in any

way. Such action disturbs the exact

alignme n t o f th e ro llin g p a r ts o f the m ac h in e

and requires extensive re-alignment. You

can b e cru shed o r seriou sly 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

Do not attempt to move the laminator across

without trained and qualified riggers. You

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.

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.

IN F O RM A T ION

GBC Film Group's warranty does not

cover malfun ction of the equipm ent du e to

mishandling and / or tipping. GBC Films

Gr o u p b ea rs n o re sp o n sib ility fo r p ers on a l

injury or damage due to moving the

lam in a to r im p r op e rly .

Page 1 - 6

© GBC Films Group February 2001

SafetyOrca III/ Orca III T 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.

© GBC Films Group February 2001

Page 1 - 7

Safety Orca III/ Orca III T 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

© GBC Films Group February 2001

SafetyOrca III/ Orca III T 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 au ge 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 290

o

F ( 143 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

o

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.

© GBC Films Group February 2001

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.

Page 1 - 9

Safety Orca III/ Orca III T Operation and Maintenance Manual

1.9 Applications

CAUTION

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.

IN FORMATION

Beca use th e O rca III T h as a n u p p er

Teflon coa ted ro ller, your resu lts m ay

vary when d oing an encapsulation process.

TM

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.

Page 1 - 10

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.

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.

© GBC Films Group February 2001

SafetyOrca III/ Orca III T Operation and Maintenance Manual

IN FO RMAT ION

Use film brake tension to control the

separa tion po int of the r elease liner.

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

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.

CAUTION

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.

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

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.

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 env ironment.

INFORMATION

Ex c es siv e pressu r e will cause the

substrate to bow or flatten.

© GBC Films Group February 2001

Page 1 - 11

Safety Orca III/ Orca III T 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.

Page 1 - 12

© GBC Films Group February 2001

SafetyOrca III/ Orca III T Operation and Maintenance Manual

CAUTION

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.

CAUTION

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

CAUTION

CLEANING HEATED ROLLERS CAN

IGNITE THE FUMES!

CAUTION

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.

CAUTION

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.

© GBC Films Group February 2001

Page 1 - 13

Safety Orca III/ Orca III T Operation and Maintenance Manual

1.12 Label locations

WARNING

!

ACHTUNG

Posted at various locations on the Orca III/

Orca III T 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.

© GBC Films Group February 2001

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 III/ Orca III T 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 Label Placement
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!

© GBC Films Group February 2001

Page 1 - 15

Safety Orca III/ Orca III T Operation and Maintenance Manual

y

p

y

p

g

p

g

y

p

g

y

pp

g

g

p

g p

g

p

pap

p

p

y

g

y

y

g

g

y

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 )

WARNING

!

III

A

C

R

O

Pro - Tech

C

B

G

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 )

SAFETY
INSTRUCTIONS
SICHERHEITS­RICHTLINIEN
CONSIGNES DE
SECURITE

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

labels before

o

erating this machine.

a trained person is to be

2. Onl
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.
Follow lockout

rocedures b e fore

.

servicin

4. Never reach into the machine for an

reason unless the machine is at a
COMPLETE STOP.

ed in

5. Never leave the machine sto

such a manner that another worker can
start the machine w hile you are workin
on or within the m achine.

6. Never change or de fe at the function of

electrical interlocks or other machine
" shutdown " switches.

7. Befor e sta rtin

this machine, che ck that:

ersons are clear of the machine.

- All

- No maintena nce w ork is bein

erformed

on the ma chine .

uards are in place.

-All

-All

arent rolls are w e ll ch ucke d in the

unwind stands.

er scraps,

- The machin e is free of

wra

s and jams.

otential hazard of entaglement

8. There is

item s such as

in this machine ca used b
lon

hair, loose clothing, and jewelry.

our clothing and hair fit

Make sure

to your body and that all jewelry,

closel
rin

s and watches are removed.

Front of cabinet

Page 1 - 16

© GBC Films Group February 2001

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 III/ Orca III T 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 .

© GBC Films Group February 2001

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

Warranty Orca III/ Orca III T 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

© GBC Films Group February 2001

3.0 Specifications

Specifications provide all of the technical data for

the Orca III/ Orca III T Laminator.

3.1 General

SpecificationsOrca III/ Orca III T Operation and Maintenance Manual

Description:

Features:

• High level, wide format color finisher for the sheet fed

ink jet and electrostatic market. The Orca III/ Orca
III T is a self standing, bi-directional laminator/
transfer machine.

• Three swing out film unwinds ( 1 upper , 2 lower )

• One swing out print unwind

• Four rewinds ( 1 upper front, 1 upper rear , 1 lower

front and 1 lower rear )

• Infeed and oufeed tables

• Footswitch

• Bi-directional operations

• Four emergency stop push buttons ( E-STOPs )

• Front and rear emergency cables ( E-CABLEs )

• Photo-electric nip sensors ( PHOTO-EYEs )

• Independent top and bottom heater units

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

• Five repositionable web idlers

• T wo removable slitter idlers ( 1 front, 1 rear )

• T wo removable table 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

• Infeed and outfeed slitters

Applications:

© GBC Films Group February 2001

• Single sided lamination

• Encapsulation

• Mounting

• Decaling

• Transfer

Page 3 - 1