GBC ORCA-IV Operation Manual

Image transfer

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Part Number 930-009 Rev. A

Do not duplicate without written permission

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De Forest, Wisconsin 53532

GBC Pro-Tech

4151 Anderson Road

Tel: 608-246-8844

Fax: 608-246-8645

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Summary of Contents for GBC ORCA-IV

Page 1 IN G M IS E EN G AR Part Number 930-009 Rev. A © 1998 GBC Pro-Tech Do not duplicate without written permission 3200 3200 IN S S IC T IO R IC L IN E IT IE N S É...
Page 2 The information in this publication is provided for reference and is believed to be accurate and complete. GBC Pro-Tech is not liable for errors in this publication or for incidental or consequential damage in connection with the furnishing or use of the information in this publication, including, but not limited to, any implied warranty of fitness or merchantabil- ity for any particular use.
Page 3: Table Of Contents
ORCA-IV Image Transfer Laminator Operation Manual Caution/Warning Label Locations ... 1-5 Preinstallation Checklist... 2-1 Unpacking... 2-4 Setup ... 2-5 Leveling ... 2-5 Startup ... 2-6 Safety... 3-1 Audible Signals ... 3-3 Operator Controls ... 3-4 Front Control Panel... 3-4 Front Clutch/Brake Panel... 3-6 Rear Control Panel ...
Page 4 ORCA-IV Image Transfer Laminator Operation Manual Cleaning ... 4-1 Lubrication ... 4-3 Adjusting the Kick Cable... 4-3 Contacting Technical Support... 4-4 Output Troubleshooting Guide... 4-6 Limited Warranty... 5-1 Exclusions to the Warranty ... 5-1 © GBC Pro-Tech 1998 October...
Page 5 This action stops the machine completely and raises the rolls. In addition, the rolls of the ORCA-IV can reach tem- peratures of over 290 F (143 C). At these tempera- tures you can be burned if the rolls are touched during set-up, operation or servicing.
Page 6 Figure 1-1: Using the Emergency Stop Buttons In addition, the ORCA-IV is equipped with two emer- gency stop kick cables located at the lower front and back of the image transfer laminator. ORCA-IV Image Transfer Laminator Operation Manual...
Page 7: Cleaning
M IS Switch/ Lockout Figure 1-4: Machine Reset Button Despite the safety features built into the ORCA-IV, extreme caution must be used when operating or ser- vicing the unit. READ THE FOLLOWING WARN- INGS AND CAUTIONS BEFORE ATTEMPTING TO OPERATE OR SERVICE THE ORCA-IV IMAGE TRANSFER LAMINATOR.
Page 8 Wear rubber gloves. Use only on cool rolls. Cleaning heated rolls can ignite the fumes. ORCA-IV Image Transfer Laminator Operation Manual Raise the upper main roll when the image transfer laminator is not in operation. Prolonged contact can damage the rolls.
Page 9 You can be crushed or seriously injured. The ORCA-IV Image Transfer Laminator is a large and heavy piece of equipment. It is necessary to employ LICENSED RIGGERS ONLY to move the machine.
Page 10 BEFORE CONNECTING TO THE Model No. Serial No. I.T.E 6N10 SUPPLY ® Amps Phase Wires MADE IN U.S.A. ORCA-IV Image Transfer Laminator Operation Manual Located WARNING Inside ACHTUNG Cabinet MISE EN GARDE O LL el ry ry . ar ea...
Page 11 ORCA-IV Image Transfer Laminator Operation Manual The following are typical safety hazard decals used on GBC Pro-Tech machines, with a brief description (“Mean- ing” column) of each decal. Decal WARNING ACHTUNG MISE EN GARDE WARNING WARNING ACHTUNG ACHTUNG MISE EN GARDE...
Page 13: Preinstallation Checklist
ORCA-IV Image Transfer Laminator Operation Manual GBC Pro-Tech is committed to a program of ongoing product improvement. As a result, we are providing these instructions so that you can ensure that your new ORCA-IV Laminator is properly and securely unpacked, moved and installed.
Page 14 5 gallon (20 liter) storage tank is appropriate. IMPORTANT The air supply to the laminator must be clean and dry or the machine will be damaged. ORCA-IV Image Transfer Laminator Operation Manual © GBC Pro-Tech 1998 October...
Page 15 ORCA-IV Image Transfer Laminator Operation Manual 38.4" (.98m) 50" (1.27m) © GBC Pro-Tech 1998 October 4' x 6' (1.2m x 2m) Work Table on Wheels Rear 85" (2.16m) Front 153" (3.89m) 4' x 6' (1.2m x 2m) Work Table on Wheels...
Page 16 Bill of Lad- ing. The ORCA-IV Image Transfer Laminator is shipped encased in shrink wrap via Air Ride Van. To unpack the machine: 7.
Page 17: Setup
ORCA-IV Image Transfer Laminator Operation Manual NOTE A word about international shipments: As these are heavy pieces of equipment, GBC Pro-Tech takes every precaution to ensure that our image transfer lamina- tors are properly crated to the highest standards. Before machines leave our loading dock, they are pre- treated with a VCI protective film to provide total cor- rosion protection.
Page 18: Startup
8. Remove the four metal casters after the machine is leveled (casters provided for transportation only). ORCA-IV Image Transfer Laminator Operation Manual The first time the image transfer laminator is started and every time it is serviced you should use the follow- ing checklist to confirm that the unit is operating prop- erly and that all safety mechanisms are functioning.
Page 19 ORCA-IV Image Transfer Laminator Operation Manual Is the safety system on the doors functioning. Open any door of the image transfer laminator. The rolls should slow to 3.0 ft/min (1 m/min) with the doors open. You should not be able to increase the speed of the machine above 3.0 ft/min (1 m/min).
Page 21: Safety
This action stops the machine completely and raises the rolls. In addition, the rolls of the ORCA-IV can reach tem- peratures of over 290 F (143 C). At these tempera- tures there is a danger of a severe burn if the rolls are touched during set-up, operation or servicing.
Page 22 Figure 3-1: Using the Emergency Stop Buttons In addition, the ORCA-IV is equipped with two emer- gency stop kick cables located at the lower front and back of the image transfer laminator. ORCA-IV Image Transfer Laminator Operation Manual...
Page 23: Audible Signals
ORCA-IV Image Transfer Laminator Operation Manual Kick Cable Reset Button Figure 3-3: Kick Cable Reset Button Machine Reset Procedure Perform this procedure whenever an emergency stop button or kick cable is activated or when the power to the machine is turned on.
Page 24: Operator Controls
Operation The operator controls for the ORCA-IV Image Transfer Laminator are located on the front and rear of the machine, to the right of the operator positions. The names and functions of these controls are as follows: )URQW &RQWURO 3DQHO...
Page 25 ORCA-IV Image Transfer Laminator Operation Manual 8. ROLL TEMPERATURE - Provides a readout of the temperature of the upper main roll and the set- point for the desired temperature adjustment. Press the star button on the temperature controller to see or change the set point.
Page 26 Automatic Tension mode, the indicator displays the material web tension you set. Once the motor ORCA-IV Image Transfer Laminator Operation Manual arrow is pressed and the machine starts, the com- puter calculates the appropriate pressure to attain the required web force based on the roll size.
Page 27 ORCA-IV Image Transfer Laminator Operation Manual 11. LOWER FRONT BRAKE PERCENT BRAK- ING FORCE - Indicates the web force (tension) for this brake as a percentage of the total possible tension the brake can exert. What the pressure indi- cator displays changes depending upon whether the motor is on or off and what mode you are operating the machine under.
Page 28: Rear Control Panel
This pres- sure stays set until you change it. The computer will not override your setting or change the display. ORCA-IV Image Transfer Laminator Operation Manual 5. SPEED/ACCUMULATOR DISPLAY - Dis- plays either the accumulator or speed, depending...
Page 29 ORCA-IV Image Transfer Laminator Operation Manual 12. ACCUMULATOR RESET - Resets the accumu- lator. 13. SPEED/ACCUMULATOR TOGGLE - Toggles control between the speed and the accumulator. 14. MOTION CONTROL FORWARD/STOP/ REVERSE - Controls the direction of the drive system, forward, reverse, or stop.
Page 30 Once the motor arrow is pressed and the machine starts, the computer calculates the 3-10 ORCA-IV Image Transfer Laminator Operation Manual appropriate pressure to attain the required web force based on the roll size. The indicator then changes to read the actual air pressure (in psi) sent to the clutch/brake.
Page 31: Heating
ORCA-IV Image Transfer Laminator Operation Manual Setup of the ORCA-IV Image Transfer Laminator is quick and straightforward when instructions are fol- lowed exactly. IMPORTANT Use a lift to load and unload rolls larger than 50 yards. They can weigh up to 500 lbs and can crush you.
Page 32: Setting The Slitter
This machine is designed to do transfer using complete systems provided by companies such as GBC Pro- Tech, 3M, or Rexam. This system includes the paper, inks, vinyl and overlaminate films specifically matched to offer excellent performance.
Page 33 ORCA-IV Image Transfer Laminator Operation Manual Tools required: • " T-handle wrench • Tape measure To load film: 1. Retract the shaft locking plungers and remove the shafts. 2. Slide the shaft into the new roll of material until the end plate is tight to the end of the material.
Page 34: Film Spacing
3-14 ORCA-IV Image Transfer Laminator Operation Manual To advance the vinyl without the paper: Release all the tension on the transfer media web. Start the vinyl web. If the paper is not stuck to the vinyl, only the vinyl web will advance.
Page 35: Process Control Charts
This section contains a completed chart for the basic operation of the image transfer laminator. GBC Pro-Tech image transfer laminators respond in a Tape very accurate and repeatable manner. The chart pro- vides a way to set up each time, every time for repeat- able performance by assuring that all controls are set to optimum.
Page 36: Procedure
It is very important that the ORCA-IV Image Transfer Laminator is shut down in proper manner. If not, the rolls can be damaged or destroyed.
Page 37 ORCA-IV Image Transfer Laminator Operation Manual Main Product Rewind (Finished Graphic) Marking Film (Vinyl) Like 3M (8620, 8640, etc.) Used Transfer Media (Rewind) Top Heater Status 290 °F (143 °C) Speed 1-10 fpm (.3-3.0 m/min) max Drive Direction Forward Drive Mode...
Page 39 ORCA-IV Image Transfer Laminator Operation Manual Performing regular maintenance on the ORCA-IV Image Transfer Laminator is critical to the proper oper- ation of the machine. A maintenance schedule and a section of procedures for disassembling and reassem- bling the serviceable areas of the image transfer lami- nator are included in this section.
Page 40 Harsh chemicals like toluene, acetone or MEK destroy the silicone covering of the rolls. ORCA-IV Image Transfer Laminator Operation Manual To clean the cabinet and covers: 1. Using a damp cotton terry cloth (water only), clean the exterior of the image transfer laminator.
Page 41 ORCA-IV Image Transfer Laminator Operation Manual Tools required: • " hex wrench • High temperature grease or lithium grease • Grease gun • Heavy weight gear oil • Soft cloth To lubricate the image transfer laminator: IMPORTANT Do not lubricate the image transfer laminator when it is hot.
Page 42 Maintenance and Troubleshooting ORCA-IV Image Transfer Laminator Operation Manual For machine parts and technical service in North America, please call: 1-608-246-8844 or fax 1-608- 246-8645. Please provide serial number when call- ing for service. In Europe, please call: +44 (0) 1844 202 440 or fax: +44 (0) 1844 202 441.
Page 43 ORCA-IV Image Transfer Laminator Operation Manual Grease Fitting Grease Fitting Pull Roll - Grease Both Sides, Bottom Roll Grease Main Roll Bearings - Both Sides, Top and Bottom Rolls Grease Fitting © GBC Pro-Tech 1998 October Maintenance and Troubleshooting Grease Fitting...
Page 44 Hints: • Check nip settings. • Check for even paper tension. • Check for proper alignment on initial setup. ORCA-IV Image Transfer Laminator Operation Manual Problem: D waves in the laminate. Hints: • Increase brake tension on laminate. • Check roll pressures.
Page 45 ORCA-IV Image Transfer Laminator Operation Manual Problem Problem Number No display. Display reads 8888. Display reads .0 and the machine does not run. Display missing the decimal point (e.g. -reads 30 instead of 3.0) Display missing the decimal point (e.g. -reads 30 instead of 3.0) but the kick cables...
Page 46 Rewind is not turning Laminate paper rewind will not turn and/or you cannot set the pressure. Roll is overheating. ORCA-IV Image Transfer Laminator Operation Manual Possible Cause a. Was the initial material webbing straight? b. Is the roll telescoped? c. Is there excessive tension? d.
Page 47 ORCA-IV Image Transfer Laminator Operation Manual Problem Problem Number I pressed the motor forward button, but the rolls would not turn! I pressed the motor reverse button, but the rolls would not turn! I pressed the main roll down push button, but the roll did...
Page 48 4-10 ORCA-IV Image Transfer Laminator Operation Manual Possible Cause a. Is there air pressure to the machine? b. Is the machine reset? a.
Page 49 ORCA-IV Image Transfer Laminator Operation Manual Problem Problem Number I pressed the totalizer-reset push button while in total- izer mode, and it did not reset and other buttons on the panel do not work either, but the controls on the other panel work.
Page 50 Slitter is not cutting. Paper rips easily at the point it is pulled off. 4-12 ORCA-IV Image Transfer Laminator Operation Manual Possible Cause a. Are the guard doors closed? b. Is the machine reset? c. Are the e-stop buttons pressed and the kick cables reset? a.
Page 51 (90) from the date of delivery to the customer for labor. This warranty is the only warranty made by GBC Pro- Tech and cannot be modified or amended. GBC Pro-Tech’s sole and exclusive liability and the customer’s sole and exclusive remedy under this...
Page 53: Specifications
ORCA-IV Image Transfer Laminator Operation Manual Table 6-1: ORCA-IV Image Transfer Laminator Specifications Characteristic Specifications Dimensions 86" x 48" x 73" (L x D x H) (2.2 x 1.2 x 1.7 m) Weight Uncrated: 3060 lbs (1814 kg) Main Rolls 62"...
Page 55: Lubrication
ORCA-IV Image Transfer Laminator Operation Manual 3-12 Accessory pack Air supply Audible signals 3-13 Centering the web Chain Lubrication 3-14 Changing film and paper Cleaning Cabinet and covers Doors Rolls Controls Front brake panel Front control panel 3-10 Rear brake panel...
Page 56: Unpacking
Paper 3-14 Vinyl Technical support Call 1-608-246-8844 or fax 1-608-246-8645 Unpacking Crate Upper main roll 3-15 Vinyl transfer Vinyl transfer and overlamination materials Warnings and cautions Warranty Exclusions ORCA-IV Image Transfer Laminator Operation Manual 3-12 © GBC Pro-Tech 1998 October...

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