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
Ph: ( 608 ) 246 - 8844
Fx: ( 608 ) 246 - 8645
Revision :
Part number : 930 - 055
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Table of Contents
Orca 80-99 Operation and Maintenance Manual
Section 5: Operations
Operation....................................................................................... 5 - 1
Front control panel diagram........................................................ 5 - 2
Rear control panel diagram......................................................... 5 - 3
Front control panel ....................................................................... 5 - 4
Rear control panel ........................................................................ 5 - 4
Setup .............................................................................................. 5 - 5
Processes ....................................................................................... 5 - 7
Process control chart (blank) ...................................................... 5 - 10
Process control diagram (blank) ................................................. 5 - 11
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
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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
Cold overlaminate/ PSA mount (Chart 2.7) ................................5 - 22
Cold overlaminate/PSA mount (Diagram 2.7) ............................5 - 23
Cold overlaminate/PSA mount (Second pass - Chart 2.8) .........5 - 24
Cold overlaminate/PSA mount (Second pass - Diagram 2.8) ....5 - 25
Cold laminate only using a sled (Chart 2.9) ................................5 - 26
Cold laminate only using a sled (Diagram 2.9) ...........................5 - 27
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Table of Contents
Orca 80-99 Operation and Maintenance Manual
Section 6: Maintenence
Daily ................................................................................................6 - 1
Monthly ...........................................................................................6 - 1
Six Month .......................................................................................6 - 2
Chain Diagram...............................................................................6 - 3
Page IV
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Orca 80-99 Operation and Maintenance Manual
Safety
SAFETY
10. Unplug this product from the wall outlet and refer
servicing to qualified service personnel under the following
conditions:
READ THIS SECTION BEFORE
OPERATING THE ORCA 80-99 LAMINATOR!
A. When the power cord is damaged or frayed.
B. If liquid has spilled into the product.
FOR YOUR SAFETY:
C. If the product has been exposed to rain or water.
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.
WARNING:
1. Read all these instructions.
Never place fingers or arms between the rollers
when they are turning or when the rollers are in
the closed position.
2. Save these instructions for later use.
3. Follow all warning and instructions marked on the
D. If the product does not operate normally when the
operating instructions are followed. Adjust only those
controls that are covered by the operating instructions
since improper adjustment of other controls may result in
damageandwilloftenrequireextensiveworkbyaqualified
technician to restore the product to normal operation.
product.
4. Unplugthisproductfromthewalloutletbeforecleaning.
Do not use liquid cleaners or aerosol cleaners. Use a
damp cloth for cleaning.
5. Do not use this product near water.
E. If the product exhibits a distinct change in performance,
indicating a need for service.
6. This product should be operated from the type of
power source indicated on the marking label. If you are
not sure of the type of power available, consult your dealer
or a qualified and certified electrician.
Safety Information
7. Do not allow anything to rest on the power cord. Do
not locate this product where persons will walk on the
cord.
WARNING:
It is vital that everyone working around the
laminator rolls avoid wearing loose-fitting clothing,
ties or dangling jewelry which could be caught in
the nip.
8. Never push objects of any kind into this
product through any slots as they may touch dangerous
voltage points or short out parts that could result in a risk
of fire or electric shock. Never spill liquid of any kind on
the product.
The GBC Pro-Tech laminator has been designed with
operator safety as a primary consideration. However,
operators must become thoroughly familiar with the
controls, and proper operation and safety features of the
machine before starting to use the unit.
9. Do not attempt to service this product yourself, as
opening or removing covers may expose you to dangerous
voltage points or other risks. Refer all servicing to service
personnel.
© GBC Films Group June 2000
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Safety
Orca 80-99 Operation and Maintenance Manual
GBC Pro-Tech laminators are powerful machines which
are designed to accomplish specific tasks such as
mounting, laminating and encapsulating. The forces
required to accomplish laminating can vary from negligible
to very large. The air-cylinder system used to provide
downward pressure on the top roll is capable of producing
forces greater than 1000 pounds (454 kg). This force
can be applied to any object that may be present in the
opening (called the nip) between the two rollers.
machine, or by stepping on or kicking the E-Stop
cable located at the bottom of the machine.
Quick action in this regard can aid in preventing or
minimizing injury or machine damage.
Because of the electrical shock hazard and the
chance that a person might get either fingers or
clothing into the drive mechanism, the cabinets
should only be opened by a qualified service person,
after the machine is shut off and the power
disconnected.
As a safety measure, the laminator is equipped with a
photoelectric eye system which stops the machine when
objects or hands are located in the nip area. Once the
blocking object is removed and the light beam is
reestablished, the laminator rolls resume turning.
Operators should use care in lowering the top laminating
roll and know how to react quickly in an emergency. The
laminator roll UP-DOWN switch is located on the front
instrument panel labeled “Laminator Roll Controls”on
the left-hand side of the machine. As the name implies,
this switch controls the up and down motion of the top
laminator roll. 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.
The machines have steel end cabinets that are bolted
closed. They serve to isolate the electrical- and drive-
system components.
WARNING:
Please note: All persons working on or near the
Orca 80-99 Laminator must be advised of the
following:
If any clothing, tools, or anything other than film
or paper is inadvertently drawn into the nip, the
action of the rolls may be halted immediately (and
the top roll lifted) by pushing or striking any of the
red E-Stop switches located at the top of the
Page 1 - 2
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Orca 80-99 Operation and Maintenance Manual
Warranty
WARRANTY
Limited Warranty
CAUTION:
Exclusions to the Warranty
This warranty specifically does not cover:
Unauthorized customer alterations will void this
warranty.
1. Damage to the laminating rollers caused by knives, razor
blades, other sharp objects, or
failure caused by adhesives.
2. Damage to the machine caused by lifting, tilting, and/or
any attempt to position the machine other than rolling on
the installed casters.
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.
3. Improper use of the machine.
GBC Pro-Tech’s sole and exclusive liability and the
customer’s sole and exclusive remedy under this
warranty shall be, at GBC Pro-Tech’s option, to
repair or replace any such defective part or product.
These remedies are only available if GBC Pro-Tech’s
examination of the product discloses to GBC Pro-
Tech’s satisfaction that such defects actually exist
and were not caused by misuse, neglect, attempt to
repair, unauthorized alteration or modification,
incorrect line voltage, contaminated air supply, or
by fire, accident or flood or other hazard.
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.
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.
© GBC Films Group June 2000
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Orca 80-99 Operation and Maintenance Manual
Specifications
ORCA 80-99
SPECIFICATIONS
Laminating Material:
Description:
Uses heat-activated 0-74” and pressure-sensitive
materials 0 - 80" (0- cm) wide with films on 3" (7.6
cm.) ID core.
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.
Laminating Speeds:
0 to 30 fpm ( 0 to 9 Mpm) with variable speed,
reversible action, START and STOP controlled via the
front instrument-panel switch or with a foot switch.
Includes:
Outfeed edge slitters for in line trimming of finished
product.
Unwind - Rewind:
Dimensions:
Three unwind positions; three rewind positions
L - 120", D - 50", H - 66" (L- 3M, D- 1.27M, H-
1.68M)
Safety Features:
(1) Photo-eye motor stop, 4 emergency stop buttons
and two kick cables to stop the machine and raise rolls.
Weight (uncrated):
2800 pounds (1270 kg)
Warranty:
One year parts warranty (except silicone roll coverings
and table tops).
Laminating Rolls:
86.5" length (220 cm) roll face with thermally
conductive silicone covered with high release silicone
surface, upper and lower rolls internally heated.
Temperature controlled by state of the art infrared
sensors with closed loop digital control systems,
independently adjustable for both top and bottom rolls.
Electric:
220 VAC, 50 or 60 Hz, single phase, 60-65 Amps.
Three phase 32 Amps (Europe only).
Compressed Air:
Laminating Opening:
2 CFM @ 100 PSI.
1_” (4.75 cm) maximum opening controlled with dual
air cylinders.
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Orca 80-99 Operation and Maintenance Manual
Installation
INSTALLATION
Uncrating the Machine
CAUTION:
6. When all the accessories have been removed from the
crate you will notice that there are two ramps that are
bolted down to the crate bottom: these will need to be
removed, using the phillips head screwdriver.
When taking the top off, care should be taken so
that the top does not fall into the crate, possibly
damaging the laminator. It might be necessary to
use two or three people for this task.
The ramps must then be secured to the edge of the crate
bottom using the screws left over from crate disassembly
(see diagram).
During the uncrating process make sure that the
screws do not end up on the floor. They can cause
problems later when trying to roll the machine into
position.
PLEASE NOTE: The Orca 80-99 Laminator is a
large and heavy piece of mechanical equipment.
Casual movement of equipment of this type can be
hazardous to the average person; and poses the
potential of serious damage to the machine.
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. In order to
minimize the possibility of damage to your new Orca 80-
99 Laminator, please follow this procedure exactly.
It will be necessary to employ qualified and
trained personnel (licensed, certified RIGGERS)
if any movement of the machine other than rolling
on a flat, level surface is contemplated.
1. The top of the crate is the first piece to be removed
(see diagram on page 4-3).
The Orca 80-99 Laminator is not designed to be
tipped up or sideways in anyway. Such action may
disturb the exact alignment of the rolling parts of
the machine and require extensive re-alignment.
GBC Pro-Tech’s warranty does not cover
malfunction of the equipment due to mis-handling
and/or tipping.
2. Next, remove one side of the crate (see diagram). At
this point it is necessary to have someone support the
remaining side of the crate while the remaining end is being
removed. Maintain support of the side until all mounting
screws are removed and the side is off the crate.
GBC Pro-Tech bears no responsibility for parties
who fail to follow these directions. Any injury or
damage to the machine due to improper moving is
the sole responsibility of the mover.
3. Remove the end of the crate (see diagram).
CAUTION:
Do not use a knife or other sharp instrument to
remove any protective covering. This could cause
irreparable damage to the machine.
Before the machine can be rolled off the crate, the foot
bolts must be freed from the four shipping hold-down
plates. Loosen the lock-nut on each of the foot bolts.
4. Remove the shrink wrap from the machine and its
contents.
Unscrew the foot bolts from the hold-down plates. Raise
but do not remove the bolts and lock nuts from the foot
bracket. (At this time, you may wish to remove the hold-
down plates from the crate to provide unrestricted removal
of the machine from the crate).
5. Once the shrink wrap is off, remove any accessories
from the crate. While doing this, take care not to scuff
the machine.
© GBC Films Group June 2000
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UNCRATING DIAGRAM
ORCA-80-99
1
5
4
INSTALL SCREWS
2
3
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Orca 80-99 Operation and Maintenance Manual
Installation
7. Once the ramps are secured and the hold down plates
are removed, the machine can be rolled off the crate
bottom. Thiswillrequirefourpeoplehandlingthemachine
and rear of the machine to insure that it has not changed.
If it has, repeat the procedure until the machine’s front,
on its four corners and carefully rolling the machine off the rear, and both sides are all level. Tighten the lock nuts
crate bottom (see diagram). The machine can now be
rolled into its final operating position.
securely to the foot brackets.
8. At this point a qualified electrician connects power to
Choose a spot with sufficient space around the unit so the machine. Make sure before supply power is provided
that there can be front and back work tables and adequate that the machine circuit breaker is in the off position. This
space for efficient material flow. Thus, a typical room area is also the point where the appropriate supply of clean,
requirement for the ORCA 80-99 is 20 X 24 feet (6.0 x dry compressed air is connected to the machine (see power
7.3 Meters) to allow use of work tables in front and to
the rear of the machine. See the suggested layout in Fig.
1-1 (page 4-4).
and air requirements).
Electrical Requirements
Once the Orca 80-99 Laminator has been placed in its
final position, optimum performance is obtained by The ORCA 80-99 is designed to accept 220 to 240-volt
installing the supplied leveling pads and leveling the AC, 50/60-Hz, 60 Amps, single phase 3 wire (USA).
machine. Install one leveling pad on each foot-bolt,
tighteningsecurely.
The peak power required by the unit is 55 Amperes. Or,
in Europe only 3-N phase 230/400 VAC, 50 Hz, 25
Amps per phase.
Lower the leveling pad to the floor by turning down the
foot bolts. Turn all the bolts sufficiently to lift all four of
the casters off the floor.
Before attempting to electrically connect or operate your
newOrca80-99Laminator, aqualified, licensedelectrician
should be consulted to ensure that an adequate power
supply, having the appropriate capacity, overcurrent
protection, safety lockouts, etc., is available; and to ensure
that the power supply of the Orca 80-99 is in accordance
with all established national and regional electrical codes
and standards.
CAUTION:
Some generation of static electricity is
unavoidable during the laminating process due to
the nature of the materials used. In order to avoid
any hazard of ignition, fire or explosion due to
static spark, it is imperative that the operating
environment is free of dust, flammable liquids, and
vapors.
CAUTION:
The air supply to the Orca must be clean and dry
Then, face the machine and place a carpenter’s level left- or the machine will be damaged.
to-right on one of the idlers. Adjust the bolts on the front
two foot brackets so that the machine is level left-to-right.
GBC Pro-Tech, will not be responsible for damage
Then, move the level to the rear of the machine and adjust to the equipment caused by improper connection,
the rear two leveling pads.
incorrect power supply or other incorrect electrical
installation.
Next, place the level front-to-rear on one of the air cylinder
brackets and adjust the bolts equally on the two foot
brackets on that side. Move the level to the other air
Before initial power is applied to the machine assure that
all toggle switches on the front and rear control panels
cylinder bracket and repeat the procedure for the other and the main power circuit breaker (inside/bottom of the
side.
left-side cabinet) are set to OFF. The AC connection is
located on the bottom/front of the left-side cabinet.
After both sides have been leveled front-to-back, go back
and check the side-to-side level condition of the front
© GBC Films Group June 2000
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Installation
Orca 80-99 Operation and Maintenance Manual
Work Table
6' X 6'
[2m x 2m]
(on w heels)
AIR SUPPLY
REAR
ELECTRICAL
SU PPLY
FRONT
10' [3m]
3'
[1m
]
Work Table
6' X 6'
[2m x 2m]
(on w heels)
20' [6m]
Fig. 1-1
SUGGESTED WORKSPACE
LAYOUT
ORCA 80-99
Page 4 - 4
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Orca 80-99 Operation and Maintenance Manual
Installation
2
1
1
1
1
1
1
4
2
2
1
Additional slitter knives
T-handle wrench, 5/16"
T-handle wrench, 1/4"
Masking Tape
Tape Measure
Rubber Cement Pick-Up
Shim Set
Leveling Pads
Outfeed Slitters
O-Rings, Brake
Oil, Air Tool
Air Requirements
CAUTION:
Do not use a knife or other sharp object to remove
the paper coverings. 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).
The air supply must be clean (free of dirt) and dry.
Moisture will cause corrosion and particles can block
pneumatic controls. Either can cause the laminator to
malfunction.
These items are needed to put the machine into operation.
RECYCLING INSTRUCTIONS:
The crate components can be reused for shipping
the machine again, or may be disassembled and
the wood and screws recycled. The shrink wrap
however, is not recyclable so therefore must be
discarded.
It is the customer’s responsibility to provide appropriate
filters and water traps for the air line before the air is routed
to the laminator.
GBC Pro-Tech suggests that the best approach to the air
requirement is to provide a dedicated small compressor
for the laminator. A standard light-duty 1/2 to 3/4
horsepower (1 kW) electric air compressor with 1.5 to
2.5 CFM output with a 2.5 - gallon (20 Liter) storage
tank is appropriate.
In order to begin operation of the machine, the Up/Down
rates for the main and pull rolls and the nips must be set
(see the Operation section of this manual). Once set, the
machine is ready for operation.
Air is fed to the machine via a 1/4-inch quick-disconnect
male connector. This connector is located below the
cabinet on the left side of the machine. (Once the air
supply and electrical power are connected to the machine,
proceed to the section on Operation in this manual).
9. Next, remove the paper coverings from the roll. After
the roll coverings have been removed, you will need to
open the accessory pack. The accessory pack contains:
Qty
Description
1
1
1
1
1
1
Set, Allen wrenches
Slittingknife
Manual
Bottle of Isopropyl Alcohol
100 % white cotton terry rags
Set, spare fuses
© GBC Films Group June 2000
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Orca 80-99 Operation and Maintenance Manual
Operations
OPERATION
Safety
5. Use a 100-percent cotton terry cloth to remove
heat-activated laminating residue, while the rolls are hot.
Follow this procedure every time heat-activated
laminates are used.
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.
WARNING:
1. Never place fingers or arms between the
rollers, both main and pull, or in roller slots no
matter what the operational status the machine is
in.
General Precautions
1. Keep razor blades, knives, and all other sharp
objects away from the chrome and silicone rollers. They
are easily damaged and very expensive to replace.
2. It is vital that everyone working around the
laminator rolls avoid wearing loose-fitting clothing,
ties or dangling jewelry, which could be caught in
the nip.
CAUTION:
Insert shims to keep the laminating and pull rolls
apart when the machine is not in use. Do not rely
on the air supply. Prolonged contact can damage
the rolls.
WARNING:
Extra caution must be used when operating the
laminator with the provided foot switch. The foot
switch acts as an “over-ride” to the photoelectric
eye; i.e., it allows the rolls to continue operation
even if the photoelectric eye detects an
obstruction near the nip.
2. Harsh chemicals such as Toluene or MEK will
destroy the silicone covering on the laminating rolls. The
rolls should be cleaned daily following the procedure
outlined in the Maintenance section of this manual.
This function is necessary a) to allow initial hand-
feeding of process materials to the rolls and b) to
prevent damage to the process at the end of a
sheet due to “curl-up” of the sheet end.
CAUTION:
If silicone adhesives contact the top or bottom roll,
remove it IMMEDIATELY using isopropyl
alcohol. It will harden within an hour.
Operators are cautioned to use the foot switch for
as short a time as practicable, and to exercise
caution when doing so.
3. Do not allow liquid silicone adhesives to contact the
top or bottom silicone roll. These materials will bond to
the roll in much less than one hour. If some adhesive
does get on the roll, wipe it off IMMEDIATELY using
isopropyl alcohol.
4. The laminating rolls will develop flat spots if left in
contact with each other when not in use. Always insert
the shims when shutting off the laminator. Do not rely on
the air supply to keep the top roller in the raised
position, as the air supply can fail at any time.
© GBC Films Group June 2000
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Operations
Orca 80-99 Operation and Maintenance Manual
A
TOP UNWINDS (3)
ON/OFF
AIR PRESSURE
ADJUSTMENT
(TOP BRAKE)
PRESSURE
PRESSURE
PRESSURE
PRESSURE
PRESSURE
ADJUST
ADJUST
ADJUST
ADJUST
ADJUST
OFF
O N
B
C
D
TOP REWIND
ON/OFF
TOP BRAKE CONTROLS
OFF
O N
LAMINATOR ROLL
UP/DOWN
TOP CLUTCH CONTROLS
AIR PRESSURE
GAUGE
OFF
O N
BOTTOM UNWIND
ON/OFF
LAMINATOR ROLL CONTROLS
OFF
O N
E
F
BOTTOM REWIND
ON/OFF
J
BOTTOM BRAKE CONTROLS
TOP HEATER SWITCH
ON/OFF LAMP
OFF
O N
RUN/JOG
SWITCH
K
BOTTOM HEATER SWITCH
ON/OFF LAMP
BOTTOM CLUTCH CONTROLS
Photoeye
JOG
RUN
G
H
FORWARD/REVERSE
SWITCH
STOP
Blocked
REV
FWD
L
PHOTOEYE
LAMP
OFF
ON
LIGHTS
SEL
RST
OFF
ON
M
SPEED CONTROL
MAIN POWER
ON/OFF
POWER
MOTOR CONTROLS
380-3440
PRO-TECH ENGINEERING, MADISON, WISCONSIN
LAMP
N
I
SPEED READOUT
MAIN POWER
SWITCH
Fig. 2-1
FRONT CONTROL PANEL
Page 5 - 2
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Orca 80-99 Operation and Maintenance Manual
Operations
A
B
D
E
TOP HEATER
ON/OFF
BOTTOM HEATER
ON/OFF
TOP HEAT
BOTTOM HEAT
OFF
ON
OFF
ON
TOP HEATER
CONTROL
BOTTOM HEATER
CONTROL
C
F
BOTTOM FAN BANK
ON/OFF
TOP FAN BANK
ON/OFF
TOP COOLING FANS
BOTTOM COOLING FANS
OFF
ON
OFF
ON
PULL ROLL CLUTCH
PRESSURE GAUGE
PRESSURE
ADJUST
AIR PRESSURE
ADJUSTMENT
OFF
ON
G
PULL ROLL CLUTCH
ON/OFF
PULL ROLLER CLUTCH
PULL ROLL
PRESSURE GAUGE
PRESSURE
PRESSURE
PRESSURE
ADJUST
ADJUST
ADJUST
AIR PRESSURE
ADJUSTMENT
OFF
ON
H
PULL ROLL
UP/DOWN
PULL ROLLER PRESSURE
BOTTOM UNWIND
TENSION PRESSURE
GAUGE
AIR PRESSURE
ADJUSTMENT
OFF
ON
I
BOTTOM BRAKE
ON/OFF
BOTTOM BRAKE
BOTTOM REWIND
TENSION PRESSURE
GAUGE
AIR PRESSURE
ADJUSTMENT
OFF
ON
J
BOTTOM CLUTCH
ON/OFF
BOTTOM CLUTCH
Fig. 2-2
REAR CONTROL PANEL
© GBC Films Group June 2000
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Operations
Orca 80-99 Operation and Maintenance Manual
Operator Controls
J. ON/OFF LAMP (Top Heater) - Denotes whether
the top heater controller is on or off.
The operator controls for the Orca laminator are
K. ON/OFF LAMP (Bottom Heater) - Denotes
operator position. See Figures 2-1 and 2-2. The names
and functions of these controls are as follows:
whether the bottom heater controller is on or off.
L. PHOTO EYE LAMP - Denotes whether or not the
PHOTO EYE is blocked.
FRONT CONTROL PANEL
M. MAIN POWER LAMP - Denotes whether or not
Please note that in each of the control sections there is a
Pressure Gauge, an On/Off switch and an Air Pressure
Regulator. The Pressure Gauge shows the operational
pressure. The On/Off switch turns the control function
on or off. The Air Pressure Regulator adjusts the air
pressure for the control function.
the main power is on the machine.
N. MAIN POWER SWITCH - Turns the
main power on and off.
A. TOP BRAKE CONTROLS - Regulation of the
REAR CONTROL PANEL
upper unwind shaft brakes.
A. ON/OFF (Top Heater Controller) - Controls
B. TOP CLUTCH CONTROLS - Front upper rewind
whether or not the top heater controller is on or off.
shaft clutch regulation.
B. TOP HEATER CONTROLLER - Controls the
upper main roll’s operational temperature and provides
a readout of the actual temperature.
C. LAMINATOR ROLL CONTROLS - Regulation of
the main laminating rolls.
D. BOTTOM BRAKE CONTROLS - Regulation of
C. ON/OFF (Top Fan Bank) - Controls whether or
the front lower unwind brake.
not the top fan bank is on or off.
E. BOTTOM CLUTCH CONTROLS - Regulation of
D. ON/OFF (Bottom Heater Controller) - Controls
the shaft’s lower front rewind clutch.
whether or not the bottom heater controller is on or off.
F. RUN/JOG SWITCH - Changes control of the
machine drive from a foot switch operation to
continuous run. It also allows the operator to “Jog” the
rolls for a short period of time.
E. BOTTOM HEATER CONTROLLER - Controls
the lower main roll’s operational temperature and
provides a readout of the actual temperature.
F. ON/OFF (Bottom Fan Bank) - Controls whether or
G. REV-FWD - This switch controls the direction of
not the bottom fan bank is on or off.
the drive system, forward or reverse.
G. PULL ROLLER CLUTCH CONTROLS-
H. SPEED CONTROL - Adjusts the speed of the
machine from zero to maximum as the control is turned
clockwise.
Regulation for the bottom pull roller clutch.
CAUTION:
I. SPEED READOUT - Digital readout of the machine
speed and total throughput in either metric or standard
units.
Use the minimum laminator roll pressure
consistent with good results. Excess pressure can
damage the laminating rollers.
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Orca 80-99 Operation and Maintenance Manual
Operations
H. PULL ROLLER PRESSURE CONTROLS -
points to remember when loadingfilm:
Regulation for the upper pull roll pressure and up/down.
CAUTION:
I. BOTTOM BRAKE CONTROL - Regulation for
the bottom rear unwind brake.
Assure that film is always mounted so that the
adhesive side will face outward from the
laminating roller.
J. BOTTOM CLUTCH CONTROL - Regulation for
the bottom rear rewind shaft’s clutch.
1. The adhesive side of the film must be oriented away
(on the outside) of the laminating roller. Otherwise it will
immediately bond to the roller, creating a major clean-
up project. Films have a shiny side and a dull side. The
dull side is the one with the adhesive. Thus, the dull side
should ALWAYS face outward from the laminating roll.
Setup
Set up of the Orca laminator is quick and
straightforward when instructions are followed directly.
When you first receive the Orca Laminator the nips
must be set before operation. The procedures for
setting the main and pull roll nips are on pages 8-1 and
8-2.
2. The film must be centered on the unwind for best
performance. This is vital when two films are fed
together. If the two films are not aligned, feed problems,
wrinkles, excess glue on rolls and other assorted
troubles will result.
Laminator Roll Pressure:
CAUTION:
1. You should use only the minimum amount of roll
pressure needed to accomplish the task. While higher
nip pressure can make the adhesive bond faster, excess
pressure can damage the rollers. Wrinkles, bubbles and
such have causes that generally cannot be cured with
more pressure.
Unless the two films fed to the nip are carefully
aligned, poor results will be seen.
Positioning Film
2. A typical roll pressure for soft substrates such as
Foamcore or Orca-Board is between 20 to 30 pounds
per square inch (PSI) or 32 to 205 kPa.
The following procedure is applicable to both the top
and the bottom feed unwinds:
3. The range of typical values for hard substrates is 25
to 50 PSI, 170 to 345 kPa.
1. Remove the ball detent retaining pins and carefully
remove the unwind/rewind shaft from its saddles. Pay
particular attention to the drive side saddles. The drive
side of the shafts must be oriented so as to not pry on
the brake or clutch protrusion. To do so would
irreparably damage both brakes and clutches.
Loading the Film
Film is loaded on the appropriate unwinds. Instructions
later in this section will cover loading and aligning film.
For applications such as encapsulation, film will be fed
from both top and bottom unwinds.
2. Slide the film onto the unwind shaft.
3. Install the shaft back into its saddles again paying
careful attention to the drive side end of the shaft.
Return ball detent pins to secure the shaft in its saddles.
The process of loading and aligning film is the same for
both the top and the bottom. There are two important
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Operations
Orca 80-99 Operation and Maintenance Manual
4. Center the film by sliding it back and forth on the
shaft until centered. As soon as the film is unwound
from the shaft, the core support will lock the roll into
position.
laminating roller(s) to reach operating temperature.
When the pre-set operating temperature has been
reached, the machine is ready to use.
5. Recheck the centering of the film roll with a tape
measure.
Cooling
(with optional cooling fans)
The following procedure is the fastest way to cool
down the machine. Natural cooling can also be
employed:
WARNING:
Normal operation of the Orca 80 laminator
involves the application of large amounts of heat
to the process materials. The surfaces of the rolls
are at a high enough temperature to cause burns if
they are touched.
1. Set the heater switches to OFF.
2. Position the two rear fan banks so that they are tilted
to direct air flow at the rolls.
Operators are cautioned not to touch, lean or fall
against the rolls of an operating laminator. Do not
become unbalanced when working near an
operating laminator.
3. Set the Laminator Roll Control to the DOWN
position.
4. Set the Forward/Reverse switch to the FORWARD
position.
Heating
5. Set the speed control to 5 fpm (150 cpm).
The following instructions should be employed when
heating one or both of the laminating rolls. The
procedure is the same for top and bottom:
6. Let the machine run until the laminating rolls return to
room temperature.
1. Set the heater switch to ON.
Paper Tips
2. Adjust the temperature controller for the desired
operating temperature using the controller push
bottoms.
1. Always cut the leading edge of a print straight so they
can be fed perpendicular to the laminating rolls.
For the Syrlec type controller use the up and down
arrows to adjust the set point. Hold down the desired
arrow until the correct set point is achieved.
Process Control Charts
Chart 2-1 and 2-1B show a blank set of process
control charts for the ORCA 80. These charts are
where you record the way you thread film through the
machine’s rolls and idlers (called webbing) and the
setting of controls and switches for each product and
process.
For the CAL3200 it is necessary to press the * button
at the same time as the up or down arrow to adjust the
set point temperature.
3. When heating the rolls, keep the top roll down and
turning at a moderate speed to prevent uneven heating.
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.
4. It will take approximately 25 minutes for the
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Orca 80-99 Operation and Maintenance Manual
Operations
B. Put a piece of contact/release paper over the print.
Otherwise, adhesive will be applied to the laminating
roller which can cause damage and the ink from
electrostatic prints will be deposited on the roll.
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.
C. Feed the print/Orca board package though the nip.
Mounting/Laminating
In the rest of this section you will find completed
process control charts for the basic operations of the
machine. These are based on Orca-Film and Orca-
Board and typical prints. If you have a special
application use the blank charts to make your own
records.
The following procedure is for one-step mounting and
heat-activated laminating using mounting board with one
adhesive side such as Orca-Board.
1. Setup:
Information:
A. The setup is shown in process chart 2-3 and 2-3B.
B. Mount the film and web as shown in chart 2-3B.
When trying new products and processes,
remember that GBC Pro-Tech’s customer service
technicians are only a phone call away.
C. Shims: Set the two front shim dials to 1/32 less than
board height.
Mounting Only
D. Laminator Roll Pressure: 40 PSI, 275 kPa.
E. Speed: 3 fpm (90 cpm).
1. Setup:
A. See process chart 2-2 and 2-2B.
B. Set Shims:
F. Upper Laminator Roll Heat: 245 degrees F, 118
degrees C.
G. Cooling: Off.
C. Upper Laminator Roll Pressure: 40 to 80 PSI, 275 -
550 kPa.
H. Film Roll Brake Pressure 20 PSI, 135 kPa.
D. Speed: 3.
2. Procedure:
E. Upper Laminator Roll Heat: 245 degrees F, 118
degrees C.
A. Feed the Orca board dull (adhesive) side up with
the print positioned as desired. A tack iron may be used
to hold the leading edge of the print in place.
Mounting Only (continued)
2. Procedure:
Encapsulation
1. Setup:
A. Lay the print on the board. Using a tack iron, tack
the leading edge of the print down onto the board so it
is held in place.
A. Refer to process chart 2-4 and 2-4B for webbing
instructions.
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Operations
Orca 80-99 Operation and Maintenance Manual
B. Trim to slightly larger than the desired finished size.
WARNING:
B. Shims: none.
C. Laminating Roller Pressure: 60 PSI, 410 kPa.
D. Pull Roller Clutch Pressure: On, 80 PSI, 550 kPa.
E. Pull Roller: Down, 60 PSI, 410 kPa.
F. Speed: 4 to 6 fpm
Take care when repositioning rewind/unwind
shafts or other heavy parts or materials, used in
the various web-up patterns. They are heavy and
can cause injury to fingers and/or toes if not
handled properly.
G. Top Roll Temperature: 220-230 degrees F (90 -
Procedure, Pass 2:
110 degrees C).
A. Prepare to put the print through a second time to
mount the print to the substrate. — anything from
wood, to Masonite, to Gator foam. Start by setting the
shims to the appropriate spacing for the material used.
H. Bottom Roll Temperature: 220-230 degrees F (90 -
110 degrees C).
I. Cooling: Optional.
B. Trim the board to the size of the print.
J. Use of the rear rewind for the finished material is
optional. It is a good procedure for long runs. If a
rewind is used in this application the clutch pressure
should be 15 PSI.
C. Align the work to the board and assure an exact fit.
Place weights on the center of the print to assure that it
does not move relative to the board during the next
steps.
2. Procedure:
D. Raise one end of the print and peel back
approximately two inches of the liner to expose the
adhesive that was applied to the print in pass 1. Fold it
under. Lay the print back down evenly and extremely
flat. From the center outward, tack the exposed
adhesive to the substrate.
A. Feed the work into the nip with the leading edge
tight and entering the nip evenly from side to side. For
thin paper from electrostatic printers in roll form, it is
best to fold over the leading edge approximately 6
inches to create a square leading edge.
E. Position the piece so that the end with the liner
peeled back is facing the nip. Insert the first one inch of
the board into the nip.
Two-Pass Mount and
Laminate (Hot and Cold)
F. Very carefully wrap the print back and over the top
laminating roll. Be sure there are no wrinkles in the nip
area. Carefully peel off the liner as the board progresses
through the laminator.
Cold/Mount Laminate
A. See charts 2-5, 2-5B, 2-6 and 2-6B for settings.
B. Assure that the mounting film from the bottom side
has the sticky adhesive side riding up around the outside
of the bottom laminating roller.
G. Trim the piece to the finished size.
Hot/Mount Laminate
Procedure, Pass 1:
A. Refer to charts 2-7, 2-7B, 2-8 and 2-8B.
B. Encapsulate image. (see chart 2-7)
© GBC Films Group June 2000
A. Run the print through to apply adhesive and
laminate.
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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. Refer to charts 2-9 and 2-9B
B. Set main roll shims to 3/16"
2. Procedure:
A. Use a starter board to get the film started and
feeding without wrinkles.
B. Lay image on the sled and place it up against the
leader board.
C. Feed image through the nip following the leader
board into the nip. Maintain paper tension on the image
until it is through the nip.
D. Cut around the image with a sharp knife to remove
it from the leader board.
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Operations
Orca 80-99 Operation and Maintenance Manual
PROCESS CONTROL CHART 2-1
Process:
Materials (top/bottom):
Front Control Panel
Adjustments
Rear Control Panel
Adjustments
Top Brake
Top Heat
Top Clutch
Bottom Heat
Laminator Roller
Bottom Brake (front)
Bottom Clutch (front)
Forward/Reverse
Speed
Top Cooling Fans
Bottom Cooling Fans
Pull Roller Clutch
Pull Roller Pressure
Bottom Brake (rear)
Bottom Clutch (rear)
Pull Roller Shims
Laminator Roller Shims
Helpful Hints/Notes:
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Orca 80-99 Operation and Maintenance Manual
Operations
(I) REMOVABLE IDLER
U
(F) FIXED IDLER
(U) UNWIND SHAFT
(R) REWIND
(M) MAIN ROLL
(P) PULL ROLL
R
OUTFEED
SLITTER
F
M
P
I
F
F
F
F
P
M
U
R
R
U
Chart 2-1B
IDENTIFICATION DIAGRAM
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Operations
Orca 80-99 Operation and Maintenance Manual
PROCESS CONTROL CHART 2-2
Process: Hot Mount, One Pass
Materials (top/bottom): /3/16" thick Hot tissue coated board
Front Control Panel
Adjustments
Rear Control Panel
Adjustments
Top Brake
OFF / NA Top Heat
ON / 245o F (118o C)
OFF / NA
OFF
Top Clutch
OFF / NA Bottom Heat
ON / 40 p.s.i. Top Cooling Fans
OFF / NA Bottom Cooling Fans
OFF / NA Pull Roller Clutch
FORWARD Pull Roller Pressure
2 - 3 f.p.m. Bottom Brake (rear)
3/16" Bottom Clutch (rear)
Pull Roller Shims
Laminator Roller
Bottom Brake (front)
Bottom Clutch (front)
Forward/Reverse
Speed
OFF
OFF / NA
OFF / NA
OFF / NA
OFF / NA
NA
Laminator Roller Shims
Helpful Hints/Notes:
Lay the image to be mounted on the board and push the board into the nip while the rolls are not
turning. Then, quickly, depress the foot switch to turn the rolls. Make sure to maintain good
paper tension while mounting the image.
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Orca 80-99 Operation and Maintenance Manual
Operations
IMAGE
245 °F
118 °C
COLD
CHART 2-2B
ONE PASS HOT MOUNT
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Operations
Orca 80-99 Operation and Maintenance Manual
PROCESS CONTROL CHART 2-3
Process: Hot Mount and Laminate, One Pass
Materials (top/bottom): / 3/16" thick Hot tissue board
Front Control Panel
Adjustments
Rear Control Panel
Adjustments
Top Brake
ON / 20 p.s.i. Top Heat
ON / 245o F (118o C)
OFF / NA
OFF
Top Clutch
OFF / NA Bottom Heat
ON / 40 p.s.i. Top Cooling Fans
OFF / NA Bottom Cooling Fans
OFF / NA Pull Roller Clutch
FORWARD Pull Roller Pressure
2 - 3 f.p.m. Bottom Brake (rear)
3/16" Bottom Clutch (rear)
Pull Roller Shims
Laminator Roller
Bottom Brake (front)
Bottom Clutch (front)
Forward/Reverse
Speed
OFF
OFF / NA
OFF / NA
OFF / NA
OFF / NA
NA
Laminator Roller Shims
Helpful Hints/Notes:
Start the overlaminate with a leader board the same thickness as the board being mounted to.
While maintaining paper tension, lay the image to be mounted on the board and follow the leader
board into the nip.
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Orca 80-99 Operation and Maintenance Manual
Operations
IMAGE
245
1°1F8
°C
COLD
CHART 2-3B
ONE PASS HOT MOUNT AND LAMINATE
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Operations
Orca 80-99 Operation and Maintenance Manual
PROCESS CONTROL CHART 2-4
Process: Encapsulation
Materials (top/bottom): 3 mil Gloss / 3mil Gloss
Front Control Panel
Adjustments
Rear Control Panel
Adjustments
Top Brake
ON / 20 p.s.i. Top Heat
ON / 230o F (110oC)
ON / 230o F (110oC)
ON
Top Clutch
ON / 20 p.s.i. Bottom Heat
Laminator Roller
Bottom Brake (front)
Bottom Clutch (front)
Forward/Reverse
Speed
ON / 60 p.s.i. Top Cooling Fans
ON / 20 p.s.i. Bottom Cooling Fans
OFF / NA Pull Roller Clutch
FORWARD Pull Roller Pressure
4 - 6 f.p.m. Bottom Brake (rear)
ON
ON / 80 p.s.i.
ON / 60 p.s.i.
OFF / NA
OFF / NA
0
Laminator Roller Shims
0
Bottom Clutch (rear)
Pull Roller Shims
Helpful Hints/Notes:
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Orca 80-99 Operation and Maintenance Manual
Operations
UNW IND
230
1°1F0
°C
230
1°1F0
°C
Chart 2-4B
ENCAPSULATION
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Operations
Orca 80-99 Operation and Maintenance Manual
PROCESS CONTROL CHART 2-5
Process: Hot Overlaminate with Pressure Sensitive Mount Adhesive
Materials (top/bottom): 3 mil Gloss / Mount Adhesive
Front Control Panel
Adjustments
Rear Control Panel
Adjustments
Top Brake
ON / 20 p.s.i. Top Heat
ON / 230o F (110oC)
OFF / NA
OFF
Top Clutch
OFF / NA Bottom Heat
Laminator Roller
Bottom Brake (front)
Bottom Clutch (front)
Forward/Reverse
Speed
ON / 60 p.s.i. Top Cooling Fans
ON / 20 p.s.i. Bottom Cooling Fans
OFF / NA Pull Roller Clutch
FORWARD Pull Roller Pressure
4 - 6 f.p.m. Bottom Brake (rear)
OFF
ON / 80 p.s.i.
ON / 60 p.s.i.
OFF / NA
OFF / NA
0
Laminator Roller Shims
0
Bottom Clutch (rear)
Pull Roller Shims
Helpful Hints/Notes:
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.
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Orca 80-99 Operation and Maintenance Manual
Operations
UNW IND
230 °F
110 °C
COLD
UNW IND
Chart 2-
5B
TWO PASS HOT OVERLAMINATE
WITH PRESSURE SENSITIVE MOUNT ADHESIVE
FIRST PASS
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Operations
Orca 80-99 Operation and Maintenance Manual
PROCESS CONTROL CHART 2-6
Process: Hot overlaminate with Pressure Sensitive Mount Adhesive (Second Pass)
Materials (top/bottom): / 3/16" Foamcore
Front Control Panel
Adjustments
Rear Control Panel
Adjustments
Top Brake
OFF / NA Top Heat
OFF / NA
OFF / NA
OFF
Top Clutch
OFF / NA Bottom Heat
Laminator Roller
Bottom Brake (front)
Bottom Clutch (front)
Forward/Reverse
Speed
OFF / NA Top Cooling Fans
OFF / NA Bottom Cooling Fans
OFF / NA Pull Roller Clutch
REVERSE Pull Roller Pressure
2 - 3 f.p.m. Bottom Brake (rear)
N/A Bottom Clutch (rear)
Pull Roller Shims
OFF
ON / 40 p.s.i.
ON / 30 p.s.i.
OFF / NA
OFF / NA
3/16"
Laminator Roller Shims
Helpful Hints/Notes:
When mounting keep an even wrap around the upper pull roll to eliminate any wrinkles due to
uneven feed of the image. 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.
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Orca 80-99 Operation and Maintenance Manual
Operations
RELEASE
LINER
COLD
COLD
Chart 2-6B
TWO PASS HOT OVERLAMINATE
WITH PRESSURE SENSITIVE MOUNT ADHESIVE
SECOND PASS
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Operations
Orca 80-99 Operation and Maintenance Manual
PROCESS CONTROL CHART 2-7
Process: Cold overlaminate with pressure sensitive mount adhesive
Materials (top/bottom): PSA Laminate/ PSA Mount Adhesive
Front Control Panel
Adjustments
Rear Control Panel
Adjustments
Top Brake
ON / 40 p.s.i. Top Heat
ON / 115° F (46oC)
OFF / NA
OFF
Top Clutch
ON / 20 p.s.i. Bottom Heat
Laminator Roller
Bottom Brake (front)
Bottom Clutch (front)
Forward/Reverse
Speed
ON / 40 p.s.i. Top Cooling Fans
ON / 20 p.s.i. Bottom Cooling Fans
OFF / NA Pull Roller Clutch
FORWARD Pull Roller Pressure
4 - 6 f.p.m. Bottom Brake (rear)
OFF
ON / 60 p.s.i.
ON / 60 p.s.i.
OFF / NA
OFF / NA
0
Laminator Roller Shims
0
Bottom Clutch (rear)
Pull Roller Shims
Helpful Hints/Notes:
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Orca 80-99 Operation and Maintenance Manual
Operations
UNW IND
RELEASE
PAPER
REW IND
115 °F
46 °C
COLD
MOUNT
ADHESIVE
UNW IND
Chart 2-7B
TWO PASS COLD OVERLAMINATE
WITH PRESSURE SENSITIVE MOUNT ADHESIVE
FIRST PASS
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Operations
Orca 80-99 Operation and Maintenance Manual
PROCESS CONTROL CHART 2-8
Process: Cold overlaminate with pressure sensitive mount adhesive (second pass)
Materials (top/bottom): / 3/16" Foamcore
Front Control Panel
Adjustments
Rear Control Panel
Adjustments
Top Brake
OFF / NA Top Heat
OFF / NA
OFF / NA
OFF
Top Clutch
OFF / NA Bottom Heat
ON / 30 p.s.i. Top Cooling Fans
OFF / NA Bottom Cooling Fans
OFF / NA Pull Roller Clutch
FORWARD Pull Roller Pressure
2 - 3 f.p.m. Bottom Brake (rear)
3/16" Bottom Clutch (rear)
Pull Roller Shims
Laminator Roller
Bottom Brake (front)
Bottom Clutch (front)
Forward/Reverse
Speed
OFF
OFF / NA
OFF / NA
OFF / NA
OFF / NA
N/A
Laminator Roller Shims
Helpful Hints/Notes:
When mounting keep an even wrap around the upper main roll to eliminate any wrinkles due to
uneven image feed.
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Orca 80-99 Operation and Maintenance Manual
Operations
115
46
°F
RELEASE
LINER
°C
COLD
Chart 2-8B
TWO PASS COLD OVERLAMINATE
WITH PRESSURE SENSITIVE MOUNT ADHESIVE
SECOND PASS
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Operations
Orca 80-99 Operation and Maintenance Manual
PROCESS CONTROL CHART 2-9
Process: Cold Overlam only (using a sled)
Materials (top/bottom): Pro-Gloss / 3/16" board (to be used for the sled)
Front Control Panel
Adjustments
Rear Control Panel
Adjustments
Top Brake
ON / 40 p.s.i. Top Heat
ON / 115o F (46oC)
OFF / NA
OFF
Top Clutch
ON / 20 p.s.i. Bottom Heat
ON / 40 p.s.i. Top Cooling Fans
OFF / NA Bottom Cooling Fans
OFF / NA Pull Roller Clutch
FORWARD Pull Roller Pressure
4 - 6 f.p.m. Bottom Brake (rear)
3/16" Bottom Clutch (rear)
Pull Roller Shims
Laminator Roller
Bottom Brake (front)
Bottom Clutch (front)
Forward/Reverse
Speed
OFF
OFF / NA
OFF / NA
OFF / NA
OFF / NA
NA
Laminator Roller Shims
Helpful Hints/Notes:
Use a starter board of the same thickness as the sled being used to start the laminate into the nip.
Lay the image on the sled and follow the leader board into the nip while maintaining paper
tension on the image being overlaminated.
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Orca 80-99 Operation and Maintenance Manual
Operations
UNW IND
RELEASE
PAPER
REW IND
3/16"STARTER
BOARD
3/16" FOAMBOARD
IMAGE
115 °F
46 °C
COLD
Chart 2-9B
COLD OVERLAMINATE
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Orca 80-99 Operation and Maintenance Manual
Maintenance
MAINTENANCE
Monthly
Introduction
Setting the Nip:
WARNING:
The gap between the two laminator rolls and the
secondary drive rollers is called the nip or roll nip. It
should be checked once a month. They should be
adjusted according to the following procedures.
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.
Main Roll Nip Setting Procedure:
1. Make sure that the machine has both power and air.
It is also necessary to make sure that the up/down rates
of the upper main roll are even prior to setting the nip; if
not follow the rate adjusting procedure on page 4-2.
Please note that the main rolls have to be cold (room
temperature) when performing this procedure.
CAUTION:
Never attempt maintenance on an operating
machine unless the instructions specifically call for
it.
2. Remove the shims and set the main roll pressure to
40 psi. Note that this must be done with the upper
main roll in its fully up position.
GBC Pro-Tech laminators require minimal
maintenance. However, regular maintenance is
essential to keep any piece of precision machinery
at peak performance. The following procedures
are segmented into daily, monthly, biannual, and
as-required procedures.
3. Loosen main roll air cylinder caps and spin them to
their fully up position.
4. Lower the upper main roll and spin down the main
roll air cylinder caps until they are finger tight and
secure.
Daily
1. Clean the Laminating Rolls:
5. Raise the upper main roll. The main roll nip is now
set.
The silicone laminating rolls can be cleaned of dust and
dirt by passing an adhesive-coated board through the
nip. (Of course, the nip should be set for the thickness
of the board used). A mild dishwashing detergent can
also be used to clean the rolls. However a better
procedure is to use isopropyl alcohol and a 100-
percent cotton terry rag.
Pull Roll Nip Setting Procedure:
1. Make sure that the machine has both power and air
and that both cabinets are open. It is also necessary to
make sure that the up/down rates of the upper pull roll
are even prior to setting the nip; if not follow the rate
adjusting procedure on the adjacent column.
Samples of these two items were supplied in the
accessory kit shipped with the machine.
2. Remove the shims and set the pull roll pressure to
40 psi. The upper pull roll should be in the fully up
position when making these adjustments.
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Maintenance
Orca 80-99 Operation and Maintenance Manual
3. Loosen both pull roll air cylinder caps and spin them
As Needed
to their fully up position.
Chain Tensioning:
4. Lower the upper pull roll and spin down the pull roll
air cylinder caps until they are finger tight and secure
them. The pull roll nip is now set.
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).
Cylinder Up/Down Rate Adjustment:
2. Using a large adjustable wrench turn the appropriate
chain tensioner until the desired chain tension is
achieved. Make sure that the chain tension of each of
the three chains is fairly close. If not it might cause
stuttering in the feed of the laminator.
If the upper laminating roll or upper pull roll moves up
or down unevenly, the cylinder flow controls need to be
adjusted.
Turn them clockwise to slow the up/down rate and
counter-clockwise to increase the up/down rate. 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 laminating roll regulator at 100 pounds per square
inch (PSI), 690 kPa, and make the necessary
adjustments to the flow controls on the bottom of the air
cylinders.
Six Months
1. Lubrication:
Disconnect the power and air supply to the machine.
Then, remove the end panels.
Lubricate the bearings on the ends of each laminating
roll (two per roll) with a high temperature grade of
bearing grease, such as Lubriplate 930-2 or equivalent
from a standard grease gun. Also lubricate the flange
bearing on the bottom secondary drive roll (pull roller).
Lubricate by hand the slots that both the upper main
and pull rolls slide up and down in.
Complete the lubrication by wiping the entire length of
the chain with an oily rag. It is also important to note
that over-lubrication of bearings is a leading cause of
bearing failure. Close the side panels, and reconnect the
electrical power and air supply.
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Orca 80-99 Operation and Maintenance Manual
Maintenance
PRIMARY
SECONDARY
CHAIN 3
CHAIN
TENSIONERS
CHAIN 4
CHAIN TENSION
DIAGRAM
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