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Summary of Contents for GBC Orca 1600
- Page 1 ORCA 1600 OPERATION & MAINTENANCE MANUAL © February 2001 GBC Films Group Do not duplicate without written permission. GBC Pro - Tech 4151 Anderson Road DeForest, WI 53532 Revision : A Ph: ( 608 ) 246 - 8844 Fx: ( 608 ) 246 - 8645...
- Page 2 The information in this publication is provided for reference and is believed to be accu- rate 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.
- Page 3 Read me file Orca 1600 Operation and Maintenance Manual This page intentionally left blank. © GBC Films Group February 2001...
- Page 4 DeForest, WI 53532 From : Company : Address : Phone number : ( Fax number : ( Re : Orca 1600 Operations and Maintenance Manual ( 930061 ) Section #: Page #: Correction (s): Additional comments: © GBC Films Group February 2001...
- Page 5 Read me file Orca 1600 Operation and Maintenance Manual This page intentionally left blank. © GBC Films Group February 2001...
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Page 6: Table Of Contents
Orca 1600 Operation and Maintenance Manual Table of Contents Table of Contents 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 1.6 Maintenance safety ..................1 - 5... - Page 7 Table of Contents Orca 1600 Operation and Maintenance Manual Section 2.0 Warranty 2.1 Limited warranty information ..............2 - 1 2.2 Exclusions to the warranty ................2 - 1 Section 3.0 Specifications 3.1 General .......................3 -1 3.2 Consumables....................3 - 2 3.3 Function ......................3 - 3 3.4 Electrical ....................3 - 4...
- Page 8 Orca 1600 Operation and Maintenance Manual Table of Contents 4.3 Unpacking ....................4 - 5 4.4 Shrink wrap ....................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...
- Page 9 Table of Contents Orca 1600 Operation and Maintenance Manual 5.3 Rear control panel ..................5 - 5 Figure 5.3.1 Rear control panel ............5 - 7 5.4 Setting temperature ..................5 - 8 5.5 In case of an emergency ................5 - 9 5.6 Film loading/ unloading ................5 - 10 5.7 Main roller nip ..................5 - 11...
- Page 10 Orca 1600 Operation and Maintenance Manual Table of Contents 6.4 Charts and diagrams .................6 - 5 Chart - 0 ( blank chart ) ................6 - 6 Diagram - 0 .....................6 - 7 Chart - 1 ( 1 pass mounting ) ..............6 - 8 Diagram - 1 .....................6 - 9...
- Page 11 Table of Contents Orca 1600 Operation and Maintenance Manual Section 7.0 Troubleshooting 7.1 Wave problems ..................7 - 1 7.2 Film problems .....................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...
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Page 12: Section 1.0 Safety
Your safety, as well as the safety of others, is W A R N IN G important to GBC Films Group. This section contains important safety information. Ind icates a poten tially hazard ou s situation w h ich , if not avoided, could resu lt in seriou s inju ry. -
Page 13: Pneumatic Safety
Orca 1600 Operation and Maintenance Manual 1.2 Pneumatic safety 1.3 Safety features The Orca 1600 laminator has been designed Important safety features of the Orca 1600 with safety as a primary consideration; however, you laminator are the emergency stop push buttons ( E-... - Page 14 E- CABLE PHOTO-EYE To engage the front or rear E-CABLE, push The Orca 1600 is equipped with three sets of in on the cable using your foot. Either cable, when PHOTO-EYEs, one at the main roller nip, one behind engaged, removes power to the motor and opens the the pull roller nip and one in front of the pull roller main roller and pull roller nips.
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Page 15: Mechanical Safety
Safety Orca 1600 Operation and Maintenance Manual 1.4 Mechanical safety 1.5 Heating safety The heating components of the Orca 1600 can reach temperatures of over 200 F ( 100 C ). W AR N IN G N ever rem ove or open any guarding or covers from the m achine. -
Page 16: Maintenance Safety
Excessive dust can damage the laminator. • 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. - Page 17 Safety Orca 1600 Operation and Maintenance Manual INFORMATION W A R N IN G Depending on the destination and customer T he O rca 1600 L am inator is a large and preference, your machine may be shipped in heavy piece of equipm ent. It is necessary to various ways.
- Page 18 Orca 1600 Operation and Maintenance Manual Safety INFORMATION CAUTION About recycling: The crate components can Do not allow the top to fall into the crate. It be reused for shipping the laminator again can damage the laminator. or can be disassembled and the wood and screws recycled.
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Page 19: Operation
Safety Orca 1600 Operation and Maintenance Manual 1.8 Operation W AR N IN G D o not operate the m achine w ith the The following symbols are positioned at control side or drive side cabinet various points in Section 5 Operation. - Page 20 Orca 1600 Operation and Maintenance Manual Safety IN F O R M AT IO N IN F O R M AT IO N W hen requiring top and bottom heat, it is T op tem perature control unit on/ off...
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Page 21: Applications
Safety Orca 1600 Operation and Maintenance Manual 1.9 Applications C AU T IO N D o not use an open blade to cut The following symbols are positioned at the w eb near the rollers. various points in Section 6 Applications. - Page 22 Orca 1600 Operation and Maintenance Manual Safety IN F O R M AT IO N C AU T IO N Speeds and tem peratures w ill affect the E xcess pressure can dam age the lam inating bond strength of therm al adhesives.
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Page 23: Troubleshooting
Safety Orca 1600 Operation and Maintenance Manual 1.10 Troubleshooting 1.11 Maintenance The following symbols are positioned at The following symbols are positioned at various points in Section 7 Troubleshooting. various points in Section 8 Maintenance. WARNING WARNING Do not wear ties, loose fit clothing or... - Page 24 Orca 1600 Operation and Maintenance Manual Safety C AU T IO N C AU T IO N C L E A N IN G H E A T E D R O L L E R S C A N...
- Page 25 1.12 Label locations W A R N IN G A C H T U N G Posted at various locations on the Orca 1600 Laminator are important safety labels. Pay careful M IS E E N G A R D E attention to these labels at all times! Figure 1.12.1...
- Page 26 Orca 1600 Operation and Maintenance Manual Safety S AF E T Y IN S T R U C T IO N S S IC H E R H E IT S - R IC H T L IN IE N...
- Page 27 Safety Orca 1600 Operation and Maintenance Manual Figure 1.12.1 Label placement W A R N IN G A C H T U N G M ISE EN G A R D E W A R N IN G A C H T U N G...
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Page 28: Section 2.0 Warranty
( 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. THE WARRANTY MADE HEREIN IS IN... - Page 29 • Any commissioning or service engineer must be of competent nature, trained and qualified to GBC Pro- Tech standards to fulfill that job. This person will have completed and passed the full service training course from GBC Pro-Tech.
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Page 30: Section 3.0 Specifications
Orca 1600 Laminator. 3.1 General Description: • Mid level, wide format color finisher for the sheet fed ink jet market. The Orca 1600 is a self standing, bi-directional laminator.. Features: • Two swing out film unwinds ( 1 upper, 1 lower ) •... -
Page 31: Consumables
Specifications Orca 1600 Operation and Maintenance Manual 3.2 Consumables Film types: • Pressure sensitive laminates • Pressure sensitive adhesives • Low melt laminates • Thermal laminates • Thermal adhesives Film diameters: • Up to a 10 in. roll diameter ( 25.4 cm ) Core size: •... -
Page 32: Function
Orca 1600 Operation and Maintenance Manual Specifications Section 3.3 Function Speed: • 0 - 15 ft / min ( 0 - 4.6 m / min ) Motor: • 2-1/4 horse power drive motor • Bi-directional D.C. motor Heating capabilities: • 68... -
Page 33: Electrical
Specifications Orca 1600 Operation and Maintenance Manual Section 3.4 Electrical United States and Canada: • 230 - 240 VAC, 50/60 Hz, single phase, 55 amps. Europe: • 230 - 240 VAC, Wye 3 phase, 25 amps/ phase B.T.U. output: • 34,120 B.T.U. / hour Heater wattages: •... -
Page 34: Dimensions
Orca 1600 Operation and Maintenance Manual Specifications Section 3.5 Dimensions Weight: • 2800 lbs. ( 1270 kg. ) Crated: • 2300 lbs. ( 1043 kg. ) Uncrated: Dimensions • 75 in. (H) x 43 in. (W) x 102 in. (L) - Page 35 Specifications Orca 1600 Operation and Maintenance Manual Figure 3.5.1 Dimensions 3 3 in . ( 84 c m ) 8 2 in . 6 0 in . ( 20 8 c m ) ( 15 2 c m ) Page 3 - 6...
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Page 36: Section 4.0 Installation
The laminator requires a clean, dust and vapor free environment to operate properly. It must not be located where there is air blowing directly on GBC Films Group is committed to a program of the machine ongoing product improvement. As a result, we are... - Page 37 Installation Orca 1600 Operation and Maintenance Manual The laminator requires 230 to 240 vac, 50/ 60 Hz, 55 amps. Or, in Europe only, 3-N phase, 240 vac, 32 amps/ phase. W A R N IN G T he O rca 1600 L am inator is a large and heavy piece of equipm ent.
- Page 38 Orca 1600 Operation and Maintenance Manual Installation Figure 4.1.1 Suggested Floor Layout 4 ft. x 6 ft. 8 ft 8 in (101.6 x 152 cm ) ( 220 cm ) W ork table on wheels A ir com pressor or air line drop B ack 20 ft.
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Page 39: Know Your Machine
Installation Orca 1600 Operation and Maintenance Manual Figure 4.2.3 Front view 4.2 Know your machine M o to r Before performing any procedure within this F ro nt C a rd b o a rd E -S T O P... -
Page 40: Unpacking
The laminator may arrive shrink wrapped or in a plywood crate on a c) With another person, carefully wheel your skid. Please follow the unpacking procedure Orca 1600 Laminator to the installation site. that pertains to your method of shipment. WARNING WARNING... -
Page 41: Crated
Installation Orca 1600 Operation and Maintenance Manual 4.5 Crated 4.5.1 Uncrate the laminator W A R N IN G a) Remove the top of the crate and then the sides in the order shown in Figure 4.5.1 T he O rca 1600 L am inator is a large and heavy piece of equipm ent. - Page 42 Orca 1600 Operation and Maintenance Manual Installation Figure 4.5.1 Disassembling of the crate 4.5.3 Moving the laminator a) Have the laminator removed off of the skid one of two methods: 1) Rolled off the skid and placed on the floor by licensed riggers using the included ramps.
- Page 43 Installation Orca 1600 Operation and Maintenance Manual b) Remove any plastic strapping and/or packing e) Consider the following when determining where paper taped to the rollers. to locate your machine; W AR N IN G CAUTION Do not use a knife or other sharp object to T he operating environm ent m ust be free of dust, flam m able liquids and vapors.
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Page 44: Accessory Pack
Contacts: GBC Parts ( 800 ) 790 - 7787 4.7.1 Preparation GBC Europe parts 33 - 45 - 535 - 7676 a) Ensure the power at the junction box is in the OFF position. Use a voltage meter to verify. - Page 45 Installation Orca 1600 Operation and Maintenance Manual b) Open the control side cabinet by removing the Figure 4.7.1 Single phase ( 3 wire ) four hex button head screws with a 5/32 in. allen wrench. B lu e W ires...
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Page 46: Air Connection
GBC suggests that the best approach to the air requirement is to provide a dedicated small compressor for the laminator. A standard... -
Page 47: Installing Levelers
Installation Orca 1600 Operation and Maintenance Manual b) Set the main air in pressure to 70 pounds per 4.9 Installing levelers square inch (psi) (500 kPa) by turning the air regulator knob. Leveling of the machine is a customer option. If... -
Page 48: Leveling
Orca 1600 Operation and Maintenance Manual Installation c) Place the leveler on the control side frame, not 4.10 Leveling the top of the cabinet, and level the machine from front to rear. Leveling of the machine is an important step in assuring that the equipment will run at it’s optimal speed... -
Page 49: Calibrations
Orca 1600 Operation and Maintenance Manual 4.11 Calibrations The following calibrations should be performed by a qualified GBC technician before the machine is to be operated. These calibrations may not be performed by the operator. Improper calibrations can result in poor lamination output. -
Page 50: Section 5.0 Operations
Orca 1600 Operation and Maintenance Manual Operations 5.0 Operations 5.1 Power on/ off E L E C T R IC AL WARNING S H O C K Do not wear ties, loose fit clothing or D o not turn pow er on if the pow er cord dangling jewelry while operating or is dam aged or frayed. -
Page 51: Front Control Panel
In the center position, the motor will not turn at all. The control panel on the Orca 1600 Laminator is located at the front operating position of the machine on the left ( control ) side cabinet. - Page 52 Orca 1600 Operation and Maintenance Manual Operations ( 6 ) Temperature Control Unit ( Bottom ): This ( 9 ) Main Roll Pressure Adjustment: Adjusts the unit is used to set the desired heating temperature of air pressure supplied to the main roller air cylinders.
- Page 53 Operations Orca 1600 Operation and Maintenance Manual Figure 5.2.1 Front control panel PR O TEC H EN G IN EER IN G D EFO R EST W I. U .S.A. (6 08) 246 - 8844 R S T S E L...
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Page 54: Rear Control Panel
Orca 1600 Operation and Maintenance Manual Operations ( 3 ) Clutch on / off Switch: Engages or disengages 5.3 Rear control panel air flow to the pneumatic clutch driving the lower pull roller. The lower pull roller is connected to the chain drive system via a pneumatic clutch. - Page 55 Operations Orca 1600 Operation and Maintenance Manual ( 6 ) Pull Roll up / down Switch: Signals the solenoid air valve for the pull roll air cylinders to shift to the IN F O R M AT IO N appropriate position to either raise or lower the upper pull roll.
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Page 56: Figure 5.3.1 Rear Control Panel
Orca 1600 Operation and Maintenance Manual Operations Figure 5.3.1 Rear control panel P R E S S U R E P .S .I. A D J PU LL R O LL C LU T C H P R E S S U R E... -
Page 57: Setting Temperature
Operations Orca 1600 Operation and Maintenance Manual c) Decrease main roller pressure, lower the upper 5.4 Setting temperature main roller, set a slow speed and press AUTO to allow the rollers to roll for an even heating surface. To increase or decrease temperature settings, perform the following steps. -
Page 58: In Case Of An Emergency
Orca 1600 Operation and Maintenance Manual Operations b) Resolve the emergency situation. 5.5 In case of an emergency c) If an E-STOP was depressed, turn the knob Four E-STOP buttons, two located on the left counter clockwise to disengage the E-STOP and right side from the front operating position and button. -
Page 59: Load A Roll Of Film
C le v is p in The Orca 1600 utilizes a swing out unwind arm for simple loading and unloading of film. Always pay particular attention to which side of the laminate... -
Page 60: Main Roller Nip
Orca 1600 Operation and Maintenance Manual Operations Unloading a roll of film 5.7 Main roller nip a) Cut the laminate from the web. To set the main roller nip for use with substrates can easily be obtained by setting the shim dials on the main roller to the desired opening. -
Page 61: Pull Roller Nip
Operations Orca 1600 Operation and Maintenance Manual 5.8 Pull roller nip 5.9 Shutdown procedure To set the pull roller nip for use with substrates can easily be obtained by setting the shim dials on the Perform the steps below to properly shutdown pull roller to the desired opening. -
Page 62: Section 6.0 Applications
Applications 6.0 Applications 6.1 Temperature chart The Orca 1600 can accommodate Poly-in or The temperature chart is only a starting point for Poly-out films. Poly-out means the adhesive is on the general types of laminates. For optimal output quality, you outside of the roll. -
Page 63: Helpful Hints
Orca 1600 Operation and Maintenance Manual Mounting 6.2 Helpful hints Mounting on the Orca 1600 can be achieved from the front operating position using the main rollers or from the rear operating position using the pull rollers. Heat can Pressure sensitive materials also assist with mounting, it follows the same hints as pressure sensitive materials. -
Page 64: Temp Conversion Chart
Orca 1600 Operation and Maintenance Manual Applications Brake tension 6.3 Temp conversion chart Brake tension should always be minimal. Brake tension should always be even from the top roll of film to the lower roll of film. Never use excessive amount of brake A temperature conversion chart has been included tension. -
Page 65: Figure 6.3.1 Temperature Conversion Chart
Applications Orca 1600 Operation and Maintenance Manual Figure 6.3.1 Temperature conversion chart 70.6 20.6 45.6 95.6 120.6 21.1 46.1 71.1 96.1 121.1 46.7 71.7 96.7 21.7 121.7 22.2 47.2 72.2 97.2 122.2 22.7 47.8 72.8 97.8 122.8 23.3 48.3 73.3 98.3... - Page 66 This section contains a blank process control chart and diagram for the ORCA 1600 as well as completed charts for the basic operations of the laminator. The pro- cess control charts should be kept in this manual or in a book close to the laminator.
- Page 67 Applications Orca 1600 Operation and Maintenance Manual Chart - 0 P R O C E S S C O N T R O L C H A R T O rc a 16 00 L am in a to r...
- Page 68 Orca 1600 Operation and Maintenance Manual Applications Diagram - 0 © GBC Films Group February 2001 Page 6 - 7...
- Page 69 Applications Orca 1600 Operation and Maintenance Manual Chart - 1 P R O C E S S C O N T R O L C H A R T - 1 O rca 16 00 L a m in a to r...
- Page 70 Orca 1600 Operation and Maintenance Manual Applications Diagram - 1 T h e rm a l m o u n t P rin t R e le a s e lin e r H O T C O L D S u b s tra te ©...
- Page 71 Applications Orca 1600 Operation and Maintenance Manual Chart - 2 P R O C E S S C O N T R O L C H A R T - 2 O rca 16 00 L a m in a to r...
- Page 72 Orca 1600 Operation and Maintenance Manual Applications Diagram - 2 P S A film R e le a s e lin e r P rin t O u tp u t W AR M C O L D R o ll o f p rin ts...
- Page 73 Applications Orca 1600 Operation and Maintenance Manual Chart - 3 P R O C E S S C O N T R O L C H A R T - 3 O rca 16 00 L a m in a to r...
- Page 74 Orca 1600 Operation and Maintenance Manual Applications Diagram - 3 D e c a l H o ld d e c a l h e re R e le a s e lin e r W AR M C O L D S u b s tra te ©...
- Page 75 Applications Orca 1600 Operation and Maintenance Manual Chart - 4 P R O C E S S C O N T R O L C H A R T - 4 O rca 16 00 L a m in a to r...
- Page 76 Orca 1600 Operation and Maintenance Manual Applications Diagram - 4 T h e rm a l film P rin t O u tp u t H O T C O L D R o ll o f p rin ts...
- Page 77 Applications Orca 1600 Operation and Maintenance Manual Chart - 5 P R O C E S S C O N T R O L C H A R T - 5 O rca 16 00 L a m in a to r...
- Page 78 Orca 1600 Operation and Maintenance Manual Applications Diagram - 5 D e c a l H o ld d e c a l h e re H O T R e le a s e lin e r C O L D S u b s tra te ©...
- Page 79 Applications Orca 1600 Operation and Maintenance Manual Chart - 6 P R O C E S S C O N T R O L C H A R T - 6 O rca 16 00 L a m in a to r...
- Page 80 Orca 1600 Operation and Maintenance Manual Applications Diagram - 6 T h e rm a l film P rin t O u tp u t H O T H O T R o ll o f p rin ts ( ro ll to ro ll o p tio n )
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Page 82: Section 7.0 Troubleshooting
Orca 1600 Operation and Maintenance Manual Troubleshooting Problem: D waves in the image but not in the laminate 7.0 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. - Page 83 Troubleshooting Orca 1600 Operation and Maintenance Manual Problem: Straight waves in the output Problem: Angled waves in the output on both sides Hints: • Check for insufficient main roller pressure Hints: • Check operational settings for materials • Check for insufficient pull roller pressure being used.
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Page 84: Film Problems
Orca 1600 Operation and Maintenance Manual Troubleshooting 7.2 Film problems 7.2.2 Pressure sensitive The following is a list of common film problems Problem : Silvering in the laminate you may encounter. Hints : • Add 100 - 120 F ( 37 - 49... -
Page 85: Machine Problems
You may do this by dialing 1 ( 800 ) 790 - 7787. • Be sure power is supplied to the laminator This will connect you with GBC National Service dispatch . You will be required to give the serial number of your machine when placing a service call. -
Page 86: Glossary
Orca 1600 Operation and Maintenance Manual Troubleshooting Coiling 7.4 Glossary A term used to describe an image rolling up on itself. This is caused by differences in the brake tension used between the upper and lower laminates during and application process. - Page 87 Troubleshooting Orca 1600 Operation and Maintenance Manual Media Film Term used to describe the materials used to print A two part material consisting an adhesive an image, i.e. the papers, inks, toners, etc. layer and a substrate. The adhesive and the substrate may or may not be clear.
- Page 88 A system that rolls up media. The rewind tubes that have been wound tightly. used on the Orca 1600 laminator is a prime example. Scarring Unwind The visual effect of folding papers or laminates A system that unwinds media.
- Page 89 Troubleshooting Orca 1600 Operation and Maintenance Manual This page intentionally left blank. Page 7 - 8 © GBC Films Group February 2001...
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Page 90: Section 8.0 Maintenance
Orca 1600 Operation and Maintenance Manual Maintenance 8.0 Maintenance 8.1 Maintenance Schedule INFORMATION GBC Films Group laminators require minimal maintenance. However, regular maintenance is essential to keep any piece of precision machinery at peak Below is a recommended maintenance performance. A maintenance schedule and a section of schedule. -
Page 91: Cleaning The Rollers
• 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. -
Page 92: Dust - Pre-Coated Boards
Orca 1600 Operation and Maintenance Manual Maintenance 8.3 Dust - Pre-coated boards 8.4 Dirt and PSA adhesive - Alcohol and cloth a) The main rollers must be below 110 F ( 43 C ). a) Allow the laminator to cool slightly to no higher... -
Page 93: Thermal Adhesive
Maintenance Orca 1600 Operation and Maintenance Manual d) Set a slow speed of less than 3 ft/ min. ( 91 cm/ 8.5 Thermal adhesive min. ). a) Allow the laminator to cool slightly, no higher e) Put on the rubber gloves and use the isopropyl... -
Page 94: Clean The Laminator
Orca 1600 Operation and Maintenance Manual Maintenance d) Set a slow speed of less than 3 ft/ min. ( 91 cm/ 8.6 Clean the laminator min. ). C AU T IO N ELECTRICAL S H O C K D o N O T pick or pull heat activated adhesive Remove power from the laminator before off the rolls w hen they are cold. - Page 95 Maintenance Orca 1600 Operation and Maintenance Manual 8.7 Clean the control panels ELECTRICAL S H O C K Remove power from the laminator before cleaning. You can be severely shocked, electrocuted or cause a fire. a) Use a terry cloth towel to wipe he control panels.