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Summary of Contents for GBC 80-99
- Page 1 ORCA 80-99 OPERATION & MAINTENANCE MANUAL © June 2000 GBC Pro-Tech Do not duplicate without written permission. GBC Pro - Tech 4151 Anderson Road DeForest, WI 53532 Revision : Ph: ( 608 ) 246 - 8844 Fx: ( 608 ) 246 - 8645...
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Page 2: Table Of Contents
Orca 80-99 Operation and Maintenance Manual Section 1: Safety Safety features ... 1 - 1 Section 2: Warranty Limited warranty information ... 2 - 1 Exclusions to the warranty ... 2 - 1 Section 3: Specifications Section 4: Installation Uncrating ...4 - 1 Uncrating Diagram ...4 - 2... - Page 3 Hot mount (Chart 2.2) ... 5 - 12 Hot mount (Diagram 2.2) ... 5 - 13 Hot mount/Laminate (Chart 2.3) ... 5 - 14 Hot mount/Laminate (Diagram 2.3) ... 5 - 15 Page II Orca 80-99 Operation and Maintenance Manual © GBC Pro - Tech June 2000...
- Page 4 Orca 80-99 Operation and Maintenance Manual Table of Contents Encapsulation (Chart 2.4) ... 5 - 16 Encapsulation (Diagram 2.4) ...5 - 17 Hot laminate/PSA mount (Chart 2.5) ...5 - 18 Hot laminate/PSA mount (Diagram 2.5) ...5 - 19 Hot laminate/PSA mount (Second pass - Chart 2.6) ...5 - 20 Hot laminate/PSA mount (Second pass - Diagram 2.6) ...5 - 21...
- Page 5 Table of Contents Section 6: Maintenence Daily ...6 - 1 Monthly ...6 - 1 Six Month ...6 - 2 Chain Diagram...6 - 3 Page IV Orca 80-99 Operation and Maintenance Manual © GBC Pro - Tech June 2000...
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Page 6: Safety Features
OPERATING THE ORCA 80-99 LAMINATOR! FOR YOUR SAFETY: Your safety as well as the safety of others is important to GBC Pro-Tech. In this instruction and on the product are important safety messages. Read these messages carefully. 1. Read all these instructions. - Page 7 Before turning this switch to the DOWN position, assure that nothing is in the nip area. Most GBC Pro-Tech machines are designed to heat the lamination rollers. Temperatures can be set to over 200 degrees F (100 degrees C). Thus there is a danger of a severe burn if the rollers are touched during set-up or operation.
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Page 8: Section 2: Warranty
CAUTION: Unauthorized customer alterations will void this warranty. GBC Pro-Tech warrants the equipment sold is free from defects in material and workmanship for a period of one (1) year from the date of delivery to the customer. This warranty is the only warranty made by Pro-Tech and can not be modified or amended. -
Page 9: Section 3: Specifications
Orca 80-99 Operation and Maintenance Manual ORCA 80-99 SPECIFICATIONS Description: Floor-standing laminator with multiple unwind positions for high productivity heat-activated laminating, encapsulating, heat transfer and mounting. The laminator can also be used with pressure-sensitive films for cold mounting and laminating applications. -
Page 10: Section 4: Installation
To uncrate the Orca 80-99 Laminator you will need a phillips head screwdriver. It helps to have a cordless drill with the screwdriver bit, because there are quite a few screws to remove throughout this procedure. -
Page 11: Uncrating Diagram
UNCRATING DIAGRAM ORCA-80-99 INS T A L L S C R E W S... -
Page 12: Electrical Requirements
Thus, a typical room area requirement for the ORCA 80-99 is 20 X 24 feet (6.0 x 7.3 Meters) to allow use of work tables in front and to the rear of the machine. -
Page 13: Suggested Layout
Installation AIR SUPPLY ELECTRICAL SU PPLY Page 4 - 4 Orca 80-99 Operation and Maintenance Manual Work Table 6' X 6' [2m x 2m] (on w heels ) R E A R FRONT 10' [3m] Work Table 6' X 6'... -
Page 14: Air Requirements
This would cause irreparable damage to the rolls and necessitate their replacement. The Orca 80-99 laminator requires filtered air at 2 cubic feet per minute (CFM), (50 liters/minute) at a pressure of at least 100 pounds (700 kPa) per square inch (PSI). -
Page 15: Section 5: Operations
Orca 80-99 Operation and Maintenance Manual OPERATION Safety Safety is always the primary concern. If you have not read the safety information at the front of this manual, do so now. Do not attempt operation of the machine until you fully understand this safety information. -
Page 16: Front Control Panel
M A IN POWER S W ITCH Page 5 - 2 Orca 80-99 Operation and Maintenance Manual P R E S S U R E O F F T O P B R A K E C O N T R O L S... -
Page 17: Rear Control Panel
Orca 80-99 Operation and Maintenance Manual TOP HEATER ON/OFF TOP HEATER CONTROL TOP FAN BANK ON/OFF PULL ROLL CLUTCH PRESSURE GAUGE PULL ROLL PRESSURE GAUGE BOTTOM UNWIND TENSION PRESSURE G A U G E BOTTOM REWIND TENSION PRESSURE G A U G E ©... - Page 18 Page 5 - 4 Orca 80-99 Operation and Maintenance Manual J. ON/OFF LAMP (Top Heater) - Denotes whether the top heater controller is on or off. K. ON/OFF LAMP (Bottom Heater) - Denotes whether the bottom heater controller is on or off.
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Page 19: Setup
Orca 80-99 Operation and Maintenance Manual H. PULL ROLLER PRESSURE CONTROLS - Regulation for the upper pull roll pressure and up/down. I. BOTTOM BRAKE CONTROL - Regulation for the bottom rear unwind brake. J. BOTTOM CLUTCH CONTROL - Regulation for the bottom rear rewind shaft’s clutch. - Page 20 (called webbing) and the setting of controls and switches for each product and process. GBC Pro-Tech laminators respond in a very accurate and repeatable manner. The charts provide a way to set up each time, every time, for repeatable performance by assuring all controls are set to optimum.
- Page 21 Orca 80-99 Operation and Maintenance Manual The process charts are also an excellent tool for training new operators. They provide a “road map” for correct machine setup and operation. The process control charts should be kept in this manual or in a book close to the Orca. Use the machine to encapsulate the popular charts so they can withstand coffee spills and will be available for ready reference.
- Page 22 Procedure, Pass 1: A. Run the print through to apply adhesive and laminate. Page 5 - 8 Orca 80-99 Operation and Maintenance Manual B. Trim to slightly larger than the desired finished size. WARNING: Take care when repositioning rewind/unwind shafts or other heavy parts or materials, used in the various web-up patterns.
- Page 23 Orca 80-99 Operation and Maintenance Manual Operations C. Raise Main Roll (Hot). D. Reverse Motor. E. 2nd Pass: Set Nip Height and tack leading edge. Run through as liner is being pulled off. Cold Overlamination (Using a Sled) 1. Setup: A.
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Page 24: Processes
Bottom Brake (front) Bottom Clutch (front) Forward/Reverse Speed Laminator Roller Shims Helpful Hints/Notes: Page 5 - 10 Orca 80-99 Operation and Maintenance Manual Rear Control Panel Adjustments Top Heat Bottom Heat Top Cooling Fans Bottom Cooling Fans Pull Roller Clutch... - Page 25 Orca 80-99 Operation and Maintenance Manual (I) REMOVABLE IDLER (F) FIXED IDLER (U) UNWIND SHAFT (R) REWIND (M) MAIN ROLL (P) PULL ROLL © GBC Films Group June 2000 Chart 2-1B IDENTIFICATION DIAGRAM Operations OUTFEED SLIT T ER Page 5 - 11...
- Page 26 Then, quickly, depress the foot switch to turn the rolls. Make sure to maintain good paper tension while mounting the image. Page 5 - 12 Orca 80-99 Operation and Maintenance Manual Rear Control Panel Adjustments OFF / NA Top Heat OFF / NA Bottom Heat ON / 40 p.s.i.
- Page 27 Orca 80-99 Operation and Maintenance Manual Operations IMAGE 245 °F 118 °C COLD CHART 2-2B ONE PASS HOT MOUNT © GBC Films Group June 2000 Page 5 - 13...
- Page 28 While maintaining paper tension, lay the image to be mounted on the board and follow the leader board into the nip. Page 5 - 14 Orca 80-99 Operation and Maintenance Manual Rear Control Panel Adjustments ON / 20 p.s.i. Top Heat OFF / NA Bottom Heat ON / 40 p.s.i.
- Page 29 Orca 80-99 Operation and Maintenance Manual ONE PASS HOT MOUNT AND LAMINATE © GBC Films Group June 2000 IMAGE °F °C COLD CHART 2-3B Operations Page 5 - 15...
- Page 30 Forward/Reverse Speed Laminator Roller Shims Helpful Hints/Notes: Page 5 - 16 Orca 80-99 Operation and Maintenance Manual Rear Control Panel Adjustments ON / 20 p.s.i. Top Heat ON / 20 p.s.i. Bottom Heat ON / 60 p.s.i. Top Cooling Fans ON / 20 p.s.i.
- Page 31 Orca 80-99 Operation and Maintenance Manual © GBC Films Group June 2000 °F °C °F °C Chart 2-4B ENCAPSULATION Operations UNW IND Page 5 - 17...
- Page 32 The encapsulated image will have waves running 90 degrees to the feed of the film. This is due to the moisture in the mount adhesive’s release liner. Once mounted the waves disappear. Page 5 - 18 Orca 80-99 Operation and Maintenance Manual Rear Control Panel Adjustments ON / 20 p.s.i.
- Page 33 Orca 80-99 Operation and Maintenance Manual Operations UNW IND 230 °F 110 °C COLD UNW IND Chart 2- TWO PASS HOT OVERLAMINATE W ITH PRESSURE SENSITIVE MOUNT ADHESIVE FIRST PASS © GBC Films Group June 2000 Page 5 - 19...
- Page 34 During the mounting process, it is also helpful to have a table the same height as the pull roller nip to help feed the board and image into the pull rollers. Page 5 - 20 Orca 80-99 Operation and Maintenance Manual Rear Control Panel Adjustments...
- Page 35 Orca 80-99 Operation and Maintenance Manual Operations R E L E A S E LINER COLD COLD Chart 2-6B TWO PASS HOT OVERLAMINATE W ITH PRESSURE SENSITIVE MOUNT ADHESIVE SECOND PASS © GBC Films Group June 2000 Page 5 - 21...
- Page 36 Forward/Reverse Speed Laminator Roller Shims Helpful Hints/Notes: Page 5 - 22 Orca 80-99 Operation and Maintenance Manual Rear Control Panel Adjustments ON / 40 p.s.i. Top Heat ON / 20 p.s.i. Bottom Heat ON / 40 p.s.i. Top Cooling Fans ON / 20 p.s.i.
- Page 37 Orca 80-99 Operation and Maintenance Manual Operations UNW IND R E L E A S E PAPER R E W IND 115 °F 46 °C COLD MOUNT ADHESIVE UNW IND Chart 2-7B TWO PASS COLD OVERLAMINATE W ITH PRESSURE SENSITIVE MOUNT ADHESIVE FIRST PASS ©...
- Page 38 Helpful Hints/Notes: When mounting keep an even wrap around the upper main roll to eliminate any wrinkles due to uneven image feed. Page 5 - 24 Orca 80-99 Operation and Maintenance Manual Rear Control Panel Adjustments OFF / NA Top Heat OFF / NA Bottom Heat ON / 30 p.s.i.
- Page 39 Orca 80-99 Operation and Maintenance Manual Operations °F R E L E A S E °C LINER COLD Chart 2-8B TWO PASS COLD OVERLAMINATE W ITH PRESSURE SENSITIVE MOUNT ADHESIVE SECOND PASS © GBC Films Group June 2000 Page 5 - 25...
- Page 40 Lay the image on the sled and follow the leader board into the nip while maintaining paper tension on the image being overlaminated. Page 5 - 26 Orca 80-99 Operation and Maintenance Manual Rear Control Panel Adjustments ON / 40 p.s.i. Top Heat ON / 20 p.s.i.
- Page 41 Orca 80-99 Operation and Maintenance Manual Operations UNW IND R E L E A S E P A P E R R E W IND 3/16"ST A R T E R B O A R D 3/16" FOAMBOARD 115 °F IMAGE 46 °C...
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Page 42: Daily
Orca 80-99 Operation and Maintenance Manual MAINTENANCE Introduction WARNING: Some maintenance procedures require opening the cabinets while the power and air are still connected to the machine. Because of the potential for electrical shock from wiring and crushing of fingers or arms in rotating apparatus, only properly trained personnel should perform these tasks. -
Page 43: Six Month
Close the side panels, and reconnect the electrical power and air supply. Page 6 - 2 Orca 80-99 Operation and Maintenance Manual As Needed Chain Tensioning: 1. Make sure that the machine has air only, no power, and that the right (drive side) cabinet is open (see the diagram on page 8-3). - Page 44 Orca 80-99 Operation and Maintenance Manual Maintenance PRIMAR Y SECONDARY CHAIN 3 CHAIN TENSIONERS CHAIN 4 C H AIN TENSION D IAG R AM © GBC Films Group June 2000 Page 6 - 3...