GBC OORCA-III Operation Manual

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Part Number 930-402 Rev. A

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GBC Pro-Tech

4151 Anderson Road

De Forest, Wisconsin 53532

Tel: 608-246-8844

Fax: 608-246-8645

Summary of Contents for GBC OORCA-III

Page 1 25&$,,,2SHUDWLRQ 0DQXDO © 1997 GBC Pro-Tech Do not duplicate without written permission o - T el . ic ed o re n ed p er b ef tr ai 5-PT o ri rder ic in -024 -748 Inc. icat ©19...
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 merchantability for any particular use.
Page 3 Cooling ..........................3-6 Paper Tips ........................... 3-6 Process Control Charts ....................... 3-7 Mounting Only ........................3-7 Setup ..........................3-7 Procedure......................... 3-7 Mounting/Laminating ......................3-7 Setup ..........................3-7 Procedure......................... 3-7 Encapsulation ........................3-8 Setup ..........................3-8 © GBC Pro-Tech 1997 October...
Page 4 PROCESS CONTROL DIAGRAM 3-6B................3-22 PROCESS CONTROL CHART 3-7 ................... 3-23 PROCESS CONTROL DIAGRAM 3-7B................3-24 PROCESS CONTROL CHART 3-8 ................... 3-25 PROCESS CONTROL DIAGRAM 3-8B................3-26 PROCESS CONTROL CHART 3-9 ................... 3-27 PROCESS CONTROL DIAGRAM 3-9B................3-28 © GBC Pro-Tech 1997 October...
Page 5 PROCESS CONTROL CHART 3-12 ................. 3-33 PROCESS CONTROL DIAGRAM 3-12B................3-34 PROCESS CONTROL CHART 3-13 ................. 3-35 PROCESS CONTROL DIAGRAM 3-13B................3-36 Laminate Temperature Guide and Helpful Hint Sheet for GBC Pro-Tech Products..3-37 All Pressure Sensitive Materials..................3-37 Lamination........................3-37 Mounting ........................3-37 Vinyl Transfer .........................
Page 6 1000 pounds (454 kg). This force Your safety, as well as the safety of others, is is applied to any object presented in the opening important to GBC Pro-Tech. This section contains (called the nip) between the two rolls. important safety information.
Page 7 These items can get caught in the nip and choke you or you can be crushed or burned. WARNING Always use care in lowering the top laminating roll. You can be crushed or burned. © GBC Pro-Tech 1997 October...
Page 8 You can cause irreparable damage to the rolls. Use only 80% (or stronger) isopropyl alcohol or a rubber cement eraser to clean the laminating rolls. Harsh chemicals like toluene, acetone or MEK destroy the silicone covering of the rolls. © GBC Pro-Tech 1997 October...
Page 9 Tech’s warranty does not cover malfunction of the equipment due to mishandling and/or tipping. ALWAYS USE GOOD SAFETY PRACTICES GBC Pro-Tech bears no responsibility for WHEN OPERATING OR SERVICING THE personal injury or damage due to moving the LAMINATOR AND KNOW HOW TO REACT laminator improperly.
Page 10 Safety &DXWLRQ:DUQLQJ /DEHO /RFDWLRQV Posted at various locations on your ORCA-III Laminator are important safety labels. PAY CAREFUL ATTENTION TO THESE LABELS AT ALL TIMES! Figure 1-3 shows the location of each of these labels. © GBC Pro-Tech 1997 October...
Page 11 ©1994 0241 HCS, Inc. 800- 748- 800-74 8-0241 , Inc. Syst icati Reord No.103 3R-PT Haza ©19 WARNING ACHTUNG MISE EN GARDE ©1994 HCS, Inc. 800-748-0241 Reorder No.1033R-PT Figure 1-3: Locations of Safety Labels © GBC Pro-Tech 1997 October...
Page 12: Installation
Installation 6HFWLRQ ,QVWDOODWLRQ CAUTION GBC Pro-Tech is committed to a program of ongoing product improvement. As a result, we are providing Do not locate the laminator where air is these instructions so that you can insure that your blowing directly on the machine.
Page 13 1.5 to 2.5 cfm output with a 5 gallon (20 liter) storage tank is appropriate. CAUTION The air supply to the laminator must be clean and dry or the machine will be damaged. © GBC Pro-Tech 1997 October...
Page 14 3' (91 cm) 2'8" (609 cm) (81 cm) Front 4' x 6' (122 cm x 182 cm) Work Table on Wheels 8'8" (264 cm) Table Height 35-3/4" (90.5-91.5 cm) 13' (396 cm) Figure 2-1: Laminator Space Requirements © GBC Pro-Tech 1997 October...
Page 15 5 in Figure 3-4. It can fall and damage the edge of the crate bottom using the screws left laminator. over from the crate disassembly (see Figure 2-2). © GBC Pro-Tech 1997 October...
Page 16: A Note About Recycling
⇒ NOTE NEVER BLOCK THE INFRARED A word about international shipments: As these are heavy pieces of equipment, GBC Pro-Tech takes SENSORS! The rolls can overheat and cause every precaution to ensure that our laminators are a fire or seriously damage the laminator.
Page 17 You can be crushed or burned. 8. When all the measurements indicate that the machine is level, tighten down the top nuts on the foot brackets to lock the pads in their current position. © GBC Pro-Tech 1997 October...
Page 18 Are the heaters working? Verify that the top heater controller heats the top roll and the bottom heater controller heats the bottom roll. Once you have completed the startup checklist you can safely run a test sample. © GBC Pro-Tech 1997 October...
Page 20 GBC Pro-Tech laminators are powerful machines that are designed to mount, laminate and encapsulate. The forces required to accomplish these tasks can vary from negligible to very large.
Page 21 - T Emergency r bef 5025-PT Reorde r No. Stop Kick -0241 Inc. 800-748 nication System Emergency Hazard Commu ©1994 Cable Stop Kick Cable Figure 3-4: Emergency Stop Kick Cables © GBC Pro-Tech 1997 October...
Page 22 3. UPPER HEATER CONTROLLER - Provides a readout of the temperature of the upper laminating roll and the set-point for the desired temperature. © GBC Pro-Tech 1997 October...
Page 23 Changes control of the machine drive from the footswitch to continuous run. 7. PULL ROLL UP/DOWN - Sets the pull roll to the up (load) or down (operate) position. 8. PULL ROLL CLUTCH ON/OFF- Turns the pull roll clutch on or off. © GBC Pro-Tech 1997 October...
Page 24 Readjust if necessary. will occur. 8. Return the arm to its locked position and reinsert the locking pin. CAUTION Carefully align the two films being fed into the nip. If not, you will obtain poor results. © GBC Pro-Tech 1997 October...
Page 25 3. Set the Laminator Roll Control to the DOWN position. 4. Set the Forward/Reverse switch to the FORWARD positon. 5. Set the speed control to 5 fpm (150 cpm). 6. Let the machine run until the laminating rolls return to room temperature. © GBC Pro-Tech 1997 October...
Page 26 3. Feed the print/Orca-Board package through the charts for the basic operations of the laminator. nip. GBC Pro-Tech laminators respond in a very accurate 0RXQWLQJ/DPLQDWLQJ and repeatable manner. The charts provide a way to set up each time, every time for repeatable...
Page 27 It can be accomplished with either hot or cold laminate film on the top. Also, the second pass for mounting can be done by feeding from either the front or back of the laminator. © GBC Pro-Tech 1997 October...
Page 28 Be sure it is smooth on the roll, then lower 5. Lamination can be done in a second pass, if the roll. required. See chart 2-13. 5. Add infeed and outfeed slitters as needed. © GBC Pro-Tech 1997 October...
Page 29 3. Bring the vinyl up over the bottom lamination roll and through the main rolls. 4. Tape the overlaminate release liner to the upper rewind. 5. Web the overlaminate material around the upper pull roll and lower it to begin overlamination. © GBC Pro-Tech 1997 October 3-10...
Page 30 Bottom Temp. Set: Bottom Heater On/Off: REAR CONTROL SETTINGS Pull Clutch On/Off: Pull Roll Up/Down: Pull Clutch Pressure: Pull Roll Pressure: Shim Dial: Cooling: See Chart 3-1B for Webbing Outline Special Instructions: __________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ © GBC Pro-Tech 1997 October 3-11...
Page 31 IDENTIFICATION DIAGRAM (I) Removable Idler (F) Fixed Idler (U) Unwind Shaft (R) Rewind (M) Main Roll (P) Pull Roll (C) Cooling Tube (S) Slitter Idler Outfeed Slitter Small Table Large Table Infeed Slitter Outfeed Slitter © GBC Pro-Tech 1997 October 3-12...
Page 32 Pull Clutch On/Off: -- Pull Roll Up/Down: Up Pull Clutch Pressure (psi): -- Pull Roll Pressure (psi): -- Shim Dial: -- Cooling: No See Chart 3-2B for Webbing Outline Special Instructions: __________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ © GBC Pro-Tech 1997 October 3-13...
Page 33 Operation ORCA-III Operation Manual 352&(66 &21752/ ',$*5$0 % ONE PASS MOUNT (HEAT ACTIVATED ADHESIVE) Use release liner if print is heat sensitive Dial Nip Height Print Orca-Board Hot or Cold © GBC Pro-Tech 1997 October 3-14...
Page 34 Pull Clutch On/Off: -- Pull Roll Up/Down: Up Pull Clutch Pressure (psi): -- Pull Roll Pressure (psi): -- Shim Dial: -- Cooling: No See Chart 3-3B for Webbing Outline Special Instructions: __________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ © GBC Pro-Tech 1997 October 3-15...
Page 35: One Pass Mount And Laminate
Operation ORCA-III Operation Manual 352&(66 &21752/ ',$*5$0 % ONE PASS MOUNT AND LAMINATE Over- laminate Print Dial Nip Height Orca-Board Hot or Cold © GBC Pro-Tech 1997 October 3-16...
Page 36 Pull Clutch On/Off: On Pull Roll Up/Down: Down Pull Clutch Pressure (psi): 80 Pull Roll Pressure (psi): 80 Shim Dial: 0 Cooling: On See Chart 3-4B for Webbing Outline Special Instructions: __________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ © GBC Pro-Tech 1997 October 3-17...
Page 37 10 Mil Film Laminate Web Film Underneath This Idler When Using 10 Mil Film (See Detail) DETAIL Optional Outfeed Slitter Large Table Optional Infeed Slitter Optional Outfeed Slitter Paper Optional Laminate Rewind Optional Laminate Optional Laminate © GBC Pro-Tech 1997 October 3-18...
Page 38 Pull Clutch On/Off: On Pull Roll Up/Down: Down Pull Clutch Pressure (psi): 80 Pull Roll Pressure (psi): 80 Shim Dial: 0 Cooling: -- See Chart 3-5B for Webbing Outline Special Instructions: __________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ © GBC Pro-Tech 1997 October 3-19...
Page 39 Operation ORCA-III Operation Manual 352&(66 &21752/ ',$*5$0 % ENCAPSULATION (ENVELOPE FEED) Laminate Print Optional Outfeed Slitter Optional Laminate Rewind Optional Laminate Optional Laminate © GBC Pro-Tech 1997 October 3-20...
Page 40 Pull Clutch On/Off: On Pull Roll Up/Down: Down Pull Clutch Pressure (psi): 80 Pull Roll Pressure (psi): 80 Shim Dial: 3/16 (.48 cm) Cooling: -- See Chart 3-6B for Webbing Outline Special Instructions: __________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ © GBC Pro-Tech 1997 October 3-21...
Page 41 (Tip! - Keep Leading Edge Straight- Cold Parallel to Roll) Optional Paper Optional on Core Outfeed Trim Optional Infeed Trim Rewind Optional Mount Adhesive Rewind of Finished Optional Product Mount Optional Adhesive Mount Adhesive © GBC Pro-Tech 1997 October 3-22...
Page 42 Pull Clutch On/Off: On Pull Roll Up/Down: Down Pull Clutch Pressure (psi): 80 Pull Roll Pressure (psi): 20-50 Shim Dial: 3/16 (.48 cm) Cooling: -- See Chart 3-7B for Webbing Outline Special Instructions: __________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ © GBC Pro-Tech 1997 October 3-23...
Page 43 TWO PASS MOUNT AND LAMINATE (SECOND PASS) Running Can Use Main Positions Rolls If Cold Release Liner Tack Lead-In Edge to Board Starting If Hot Positions Dial Nip Height Release Liner Orca-Board Shim Dial © GBC Pro-Tech 1997 October 3-24...
Page 44 Pull Clutch On/Off: On Pull Roll Up/Down: Down Pull Clutch Pressure (psi): 80 Pull Roll Pressure (psi): 80 Shim Dial: 0 Cooling: -- See Chart 3-8B for Webbing Outline Special Instructions: __________________________________________________________ __________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________ © GBC Pro-Tech 1997 October 3-25...
Page 45 Operation ORCA-III Operation Manual 352&(66 &21752/ ',$*5$0 % COLD MOUNT/LAMINATE (WHEN MAIN ROLLS ARE HOT, ELIMATES COSTLY HEAT-UP AND COOL-DOWN TIME) Cold Laminate Mount Adhesive Optional Mount Optional Adhesive Mount Adhesive © GBC Pro-Tech 1997 October 3-26...
Page 46 Pull Clutch On/Off: On Pull Roll Up/Down: Down Pull Clutch Pressure (psi): 80 Pull Roll Pressure (psi): 80 Shim Dial: 0 Cooling: -- See Chart 3-9B for Webbing Outline Special Instructions: __________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ © GBC Pro-Tech 1997 October 3-27...
Page 47: Cold Lamination
ORCA-III Operation Manual 352&(66 &21752/ ',$*5$0 % COLD LAMINATION Pressure Sensitive Laminate Paper Cold Optional Infeed Slitter Cold Optional Paper Wound on Core Optional Outfeed Slitter Optional Edge Trim Optional Rewind Mount Adhesive Rewind © GBC Pro-Tech 1997 October 3-28...
Page 48 Pull Clutch On/Off: On Pull Roll Up/Down: Down Pull Clutch Pressure (psi): 50 Pull Roll Pressure (psi): 80 Shim Dial: 0 Cooling: On See Chart 3-10B for Webbing Outline Special Instructions: __________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ © GBC Pro-Tech 1997 October 3-29...
Page 49 (SLITTING INFEED AND OUTFEED) Overlaminate Rewind Transfer Rewind Paper Laminate Paper Transfer Paper Infeed Trim Cold Transfer Paper Unwind Outfeed Trim Transfer Paper Rewind of Cutoff Vinyl Finished Rewind Product Optional Optional Vinyl Vinyl © GBC Pro-Tech 1997 October 3-30...
Page 50 Pull Clutch On/Off: On Pull Roll Up/Down: Down Pull Clutch Pressure (psi): 50 Pull Roll Pressure (psi): 80 Shim Dial: 0 Cooling: On See Chart 3-11B for Webbing Outline Special Instructions: __________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ © GBC Pro-Tech 1997 October 3-31...
Page 51 Operation ORCA-III Operation Manual 352&(66 &21752/ ',$*5$0 % Transfer Paper Cold Optional Vinyl Vinyl Optional Vinyl © GBC Pro-Tech 1997 October 3-32...
Page 52 Pull Clutch On/Off: On Pull Roll Up/Down: Down Pull Clutch Pressure (psi): 50 Pull Roll Pressure (psi): 80 Shim Dial: 0 Cooling: On See Chart 3-12B for Webbing Outline Special Instructions: __________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ © GBC Pro-Tech 1997 October 3-33...
Page 53: Roll-To-Roll Transfer
Operation ORCA-III Operation Manual 352&(66 &21752/ ',$*5$0 % ROLL-TO-ROLL TRANSFER © GBC Pro-Tech 1997 October 3-34...
Page 54 Pull Clutch On/Off: On Pull Roll Up/Down: Down Pull Clutch Pressure (psi): 80 Pull Roll Pressure (psi): 80 Shim Dial: 0 Cooling: No See Chart 3-13B for Webbing Outline Special Instructions: __________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ © GBC Pro-Tech 1997 October 3-35...
Page 55 352&(66 &21752/ ',$*5$0 % ROLL TO ROLL COLD OVERLAMINATION Pressure Sensitive Overlaminate Edge Trim Rewind Rewind Laminate Paper Infeed Slitter Now Becomes Outfeed Slitter Cold Transferred Image On Rewind of Vinyl Finished Product Brake © GBC Pro-Tech 1997 October 3-36...
Page 56 The top roll heat should be set to 290 ºF, with as speed of 1.5-2.5 fpm. The main roll pressure should be at 90 psi. The pull roll clutch should be at 50 psi. The pull roll should be set at 75-80 psi. Always allow the transferred image to cool prior to removing the transfer paper. © GBC Pro-Tech 1997 October 3-37...
Page 58 Maintenance and Troubleshooting 6HFWLRQ 0DLQWHQDQFH DQG To clean the laminator rolls: 7URXEOHVKRRWLQJ GBC Pro-Tech laminators require minimal maintenance. However, regular maintenance is WARNING essential to keep any piece of precision machinery at peak performance. A maintenance schedule and a Exercise extreme caution while cleaning the section of procedures are included in this section.
Page 59 Be sure to set the nip for the thickness of the board used. 5. Allow the laminator to cool. © GBC Pro-Tech 1997 October...
Page 60 3. Set the main roll pressure to 30 PSI on the front control panel. Figure 4-4: Properly Set Nip 4. Screw the adjusting collars down until they seat. 5. Raise the main roll. 6. Without moving the adjusting collars, draw a zero on each collar scale. © GBC Pro-Tech 1997 October...
Page 61 4. Set the nip adjuster on each end of the laminator to zero. View the setting on the interior wall of the laminator, not from inside the open cabinets. Properly Set Nip (Distance Between Rolls is Equal) Figure 4-6: Properly Set Nip © GBC Pro-Tech 1997 October...
Page 62 5. Replace the cabinet cover and reapply power to cover in place. the laminator. 2. Loosen the nut that secures the inner chain tension adjuster sprocket using the 1- " wrench. © GBC Pro-Tech 1997 October...
Page 63 2. Tighten the nut that secures the outer chain tension adjuster sprocket using the 1- " wrench. 3. Move the adjuster sprocket until there is approximately ¾" play measured at the outer chain tension check location. © GBC Pro-Tech 1997 October...
Page 64 To correct for uneven motion, when the roll is going up, adjust the flow controls at the top of the air cylinders. To adjust for uneven lowering, set the air pressure on the © GBC Pro-Tech 1997 October...
Page 65 There is a fitting on each of the main roll bearings, pull roll bearings, and on all five idlers on the control side of the machine. 3. Lubricate the chain using a soft cloth and automotive oil. 4. Close the cabinet covers. © GBC Pro-Tech 1997 October...
Page 68 Longitudinal waves or • Check for even paper tension. • Check for insufficient main roll stuttering, jerking, or pressure excessive noise from the drive side of the laminator. Hints: • Increase chain tension, decrease unwind brake tension. © GBC Pro-Tech 1997 October...
Page 70 This warranty 2. Damage to the machine caused by lifting, tilting, is the only warranty made by GBC Pro-Tech and and/or any attempt to position the machine other cannot be modified or amended.
Page 72 Four emergency stop buttons Installation 220 to 240 VAC, 50/60 Hz, 55 Requirement A. Or, in Europe only, 3-N phase, 32 A per phase. Air: 2 cfm at 100 psi, minimum (0.5 m at 700 vPa) © GBC Pro-Tech 1997 October...
Page 108 Laminating opening, 6-3 Weight, 6-3 Laminating rolls, 6-3 Laminating speeds, 6-3 Leveling the laminator, 2-6 Loading the film, 3-4 Technical support Lubrication, 4-1–4-4 Call 1-800-236-8843, 4-13, 4-14 Two-pass mount and laminate (hot and cold), 3-8 © GBC Pro-Tech 1997 October...
Page 109 Index ORCA-III Operation Manual Unpacking, 2-4 Crate, 2-4 Upper main roll, 1-3 Warnings and cautions. See Safety Information Warranty, 5-1 © GBC Pro-Tech 1997 October...

GBC OORCA-III Operation Manual

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Summary of Contents for GBC OORCA-III

Page 12: Installation

Page 16: A Note About Recycling

Page 35: One Pass Mount And Laminate

Page 47: Cold Lamination

Page 53: Roll-To-Roll Transfer