ORCA 80-99 OPERATION & MAINTENANCE MANUAL © June 2000 GBC Pro-Tech Do not duplicate without written permission.
Orca 80-99 Operation and Maintenance Manual Table of Contents Table of Contents 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 ...............................................
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 .....................
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) ..................
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...............................................................................
Orca 80-99 Operation and Maintenance Manual Safety SAFETY READ THIS SECTION BEFORE OPERATING THE ORCA 80-99 LAMINATOR! 10. Unplug this product from the wall outlet and refer servicing to qualified service personnel under the following conditions: A. When the power cord is damaged or frayed. FOR YOUR SAFETY: B. If liquid has spilled into the product. 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.
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).
Orca 80-99 Operation and Maintenance Manual Warranty WARRANTY Limited 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.
Orca 80-99 Operation and Maintenance Manual Specifications 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. Includes: Outfeed edge slitters for in line trimming of finished product.
Orca 80-99 Operation and Maintenance Manual Installation INSTALLATION Uncrating the Machine CAUTION: 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. 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.
1 4 5 3 Orca 80-99 Operation and Maintenance Manual ] cm [59 n.
Orca 80-99 Operation and Maintenance Manual 7. Once the ramps are secured and the hold down plates are removed, the machine can be rolled off the crate bottom. This will require four people handling the machine on its four corners and carefully rolling the machine off the crate bottom (see diagram). The machine can now be rolled into its final operating position.
Orca 80-99 Operation and Maintenance Manual Work Table 6' X 6' [2m x 2m] (on w heels ) 10' [3m ] Installation AIR SUPPLY 4' [1.2m ] 24' [7.3m ] REAR ELECTRICAL SU PPLY FRONT 10' [3m] 3' [1m ] Work Table 6' X 6' [2m x 2m] (on w heels ) 20' [6m] Fig .
Orca 80-99 Operation and Maintenance Manual 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.
Orca 80-99 Operation and Maintenance Manual Operations 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. 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.
Operations Orca 80-99 Operation and Maintenance Manual A TOP UNWINDS (3) O N /OFF AIR PRESSURE ADJUSTMENT (TOP BRAKE) ADJUST PRESSURE ON OFF B TOP REWIND TOP BRAKE CONTROLS O N /OFF ADJUST PRESSURE ON OFF C LAMINATOR ROLL TOP CLUTCH CONTROLS UP/DOWN AIR PRESSURE ADJUST PRESSURE GAUGE OFF ON D B O T T O M U N W IND LAMINATOR ROLL CONTROLS O N /OFF ADJUST PRESSURE ON OFF TOP HEATER SWITCH O N /OFF LAMP J O N /OFF ADJUST PRESSURE ON OFF BOTTOM HEATER SWITCH O N /OFF LAMP E BOTTOM
Orca 80-99 Operation and Maintenance Manual Operations TOP HEATER A D ON/OFF TOP HEAT OFF TOP HEATER B CONTROL TOP FAN BANK C ON/OFF ON OFF TOP COOLING FANS OFF PULL ROLL CLUTCH PRESSURE GAUGE BOTTOM HEAT ON E BOTTOM HEATER CONTROL F BOTTOM FAN BANK ON/OFF BOTTOM COOLING FANS ON OFF PRESSURE ON ADJUST OFF ON AIR PRESSURE ADJUSTMENT G PULL ROLL PRESSURE GAUGE PULL ROLLER CLUTCH PRESSURE ADJUST OFF BOTTOM HEATER ON/OFF ON PULL ROLL CLUTCH ON/OFF AIR PRESSURE ADJUSTMENT H PULL RO
Operations Operator Controls Orca 80-99 Operation and Maintenance Manual J. ON/OFF LAMP (Top Heater) - Denotes whether the top heater controller is on or off. The operator controls for the Orca laminator are operator position. See Figures 2-1 and 2-2. The names and functions of these controls are as follows: K. ON/OFF LAMP (Bottom Heater) - Denotes whether the bottom heater controller is on or off. L. PHOTO EYE LAMP - Denotes whether or not the PHOTO EYE is blocked.
Orca 80-99 Operation and Maintenance Manual H. PULL ROLLER PRESSURE CONTROLS Regulation for the upper pull roll pressure and up/down. Operations points to remember when loadingfilm: CAUTION: I. BOTTOM BRAKE CONTROL - Regulation for the bottom rear unwind brake. J. BOTTOM CLUTCH CONTROL - Regulation for the bottom rear rewind shaft’s clutch. Setup Set up of the Orca laminator is quick and straightforward when instructions are followed directly.
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.
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. Operations B. Put a piece of contact/release paper over the print.
Operations B. Shims: none. Orca 80-99 Operation and Maintenance Manual B. Trim to slightly larger than the desired finished size. C. Laminating Roller Pressure: 60 PSI, 410 kPa. WARNING: D. Pull Roller Clutch Pressure: On, 80 PSI, 550 kPa. E. Pull Roller: Down, 60 PSI, 410 kPa. F. Speed: 4 to 6 fpm G. Top Roll Temperature: 220-230 degrees F (90 110 degrees C). H. Bottom Roll Temperature: 220-230 degrees F (90 110 degrees C).
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.
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 Top Cooling Fans Bottom Brake (front) Bottom Cooling Fans Bottom Clutch (front) Pull Roller Clutch Forward/Reverse Pull Roller Pressure Speed Bottom Brake (rear) Laminator Roller Shims Bottom Clutch (rear) Pull Roller Shims Helpful Hints/Notes: Page 5 -
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 SLIT T ER F M P I F F F P M U F R R U Chart 2-1B IDENTIFICATION DIAGRAM © GBC Films Group June 2000 Page 5 - 11
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 Clutch OFF / NA Bottom Heat Laminator Roller ON / 40 p.s.i.
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
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 Clutch OFF / NA Laminator Roller ON / 40 p.s.i.
Orca 80-99 Operation and Maintenance Manual Operations IMAGE 245 °F 118 °C COLD CHART 2-3B ONE PASS HOT MOUNT AND LAMINATE © GBC Films Group June 2000 Page 5 - 15
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) Top Clutch ON / 20 p.s.i. Bottom Heat ON / 230o F (110oC) Laminator Roller ON / 60 p.s.i. Top Cooling Fans ON Bottom Brake (front) ON / 20 p.s.i.
Orca 80-99 Operation and Maintenance Manual Operations UNW IND 230 110 °F °C 230 110 °F °C Chart 2-4B ENCAPSULATION © GBC Films Group June 2000 Page 5 - 17
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 Clutch OFF / NA ON / 230o F (110oC) Top Heat Bottom Heat OFF / NA Laminator Roller ON / 60 p.s.i. Top Cooling Fans OFF Bottom Brake (front) ON / 20 p.s.i.
Orca 80-99 Operation and Maintenance Manual Operations UNW IND 230 °F 110 °C COLD UNW IND Chart 25B TWO PASS HOT OVERLAMINATE W ITH PRESSURE SENSITIVE MOUNT ADHESIVE FIRST PASS © GBC Films Group June 2000 Page 5 - 19
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 Top Clutch OFF / NA Bottom Heat OFF / NA Laminator Roller OFF / NA Top Cooling Fans OFF Bottom Brake (front) OFF / NA Bottom Cooling Fans OFF Bottom Clutch (front) OFF / NA Pull Roller Clu
Orca 80-99 Operation and Maintenance Manual Operations RELEASE 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
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 ON / 115° F (46oC) Top Brake ON / 40 p.s.i. Top Heat Top Clutch ON / 20 p.s.i. Bottom Heat Laminator Roller ON / 40 p.s.i. Top Cooling Fans OFF Bottom Brake (front) ON / 20 p.s.i.
Orca 80-99 Operation and Maintenance Manual Operations UNW IND RELEASE 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 © GBC Films Group June 2000 Page 5 - 23
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 Top Clutch OFF / NA Bottom Heat OFF / NA Laminator Roller ON / 30 p.s.i.
Orca 80-99 Operation and Maintenance Manual Operations 115 46 °F °C RELEASE 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
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 ON / 115o F (46oC) Top Brake ON / 40 p.s.i. Top Heat Top Clutch ON / 20 p.s.i. Bottom Heat Laminator Roller ON / 40 p.s.i.
Orca 80-99 Operation and Maintenance Manual Operations UNW IND RELEASE PAPER R E W IND 3/16"ST A R T E R BOARD 3/16" FOAMBOARD IMAGE 115 °F 46 °C COLD Chart 2-9B COLD OVERLAMINATE © GBC Films Group June 2000 Page 5 - 27
Orca 80-99 Operation and Maintenance Manual Maintenance MAINTENANCE Introduction Monthly Setting the Nip: 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.
Maintenance Orca 80-99 Operation and Maintenance Manual As Needed 3. Loosen both pull roll air cylinder caps and spin them 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. Cylinder Up/Down Rate Adjustment: If the upper laminating roll or upper pull roll moves up or down unevenly, the cylinder flow controls need to be adjusted. 1.
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
