GBC Laminator ORCA IV User Manual

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© 1998 GBC Pro-Tech  
Do not duplicate without written permission  
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100  
90  
80  
70  
60  
50  
40  
30  
20  
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kPa  
700  
630  
560  
490  
420  
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SAFETY  
INSTR  
SICHEURCHTEIIOTSN-S  
RICHTLINIEN  
CONSIGNES DE  
SÉCURITÉ  
PRO-TECH  
GBC Pro-Tech  
4151 Anderson Road  
De Forest, Wisconsin 53532  
Tel: 608-246-8844  
Part Number 930-009 Rev. A  
Fax: 608-246-8645  
Download from Www.Somanuals.com. All Manuals Search And Download.  
ORCA-IV Image Transfer Laminator Operation Manual  
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Caution/Warning Label Locations.................................................................................... 1-5  
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Preinstallation Checklist................................................................................................... 2-1  
Unpacking........................................................................................................................ 2-4  
Setup ............................................................................................................................... 2-5  
Leveling ........................................................................................................................... 2-5  
Startup ............................................................................................................................. 2-6  
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Safety............................................................................................................................... 3-1  
Audible Signals ............................................................................................................ 3-3  
Operator Controls ............................................................................................................ 3-4  
Front Control Panel...................................................................................................... 3-4  
Front Clutch/Brake Panel............................................................................................. 3-6  
Rear Control Panel ...................................................................................................... 3-8  
Rear Clutch/Brake Panel ...........................................................................................3-10  
Setup ............................................................................................................................. 3-11  
Loading the Film ............................................................................................................ 3-11  
Heating .......................................................................................................................... 3-11  
Recommended Materials...............................................................................................3-12  
Films (Excluding Vinyl Transfer and Overlamination) ................................................3-12  
Vinyl Transfer and Overlamination Materials .............................................................3-12  
Setting the Slitter ...........................................................................................................3-12  
Paper Tips......................................................................................................................3-12  
Positioning the Film and Centering the Web .................................................................3-13  
Film Spacing..................................................................................................................3-14  
Operational Tips and Tricks ...........................................................................................3-14  
Changing Film and Paper ..........................................................................................3-14  
Process Control Charts..................................................................................................3-15  
Vinyl Transfer ................................................................................................................3-15  
Setup..........................................................................................................................3-15  
Procedure ..................................................................................................................3-16  
Machine Shutdown ........................................................................................................3-16  
Procedure ..................................................................................................................3-16  
© GBC Pro-Tech 1998 October  
iii  
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ORCA-IV Image Transfer Laminator Operation Manual  
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Cleaning .......................................................................................................................... 4-1  
Lubrication....................................................................................................................... 4-3  
Adjusting the Kick Cable.................................................................................................. 4-3  
Contacting Technical Support.......................................................................................... 4-4  
Output Troubleshooting Guide......................................................................................... 4-6  
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Limited Warranty.............................................................................................................. 5-1  
Exclusions to the Warranty .......................................................................................... 5-1  
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iv  
© GBC Pro-Tech 1998 October  
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ORCA-IV Image Transfer Laminator Operation Manual  
Safety  
The GBC Pro-Tech ORCA-IV is a powerful machine  
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that is designed for vinyl transfer and over-lamination.  
The forces required to accomplish these tasks are very  
large.  
DO NOT ATTEMPT TO OPERATE YOUR  
ORCA-IV IMAGE TRANSFER LAMINATOR  
UNTIL YOU HAVE READ THIS SECTION  
CAREFULLY!  
The air-cylinder system used to provide downward  
pressure on the top roll is capable of producing forces  
greater than 1000 pounds (454kg). This force is applied  
to any object presented in the opening (called the nip)  
between the two rolls.  
Your safety, as well as the safety of others, is important  
to GBC Pro-Tech. This section contains important  
safety information.  
Use care in lowering the top main roll and know how to  
react quickly in an emergency. The laminator roll UP-  
DOWN switch is located on the instrument panels.  
This switch controls the up and down motion of the top  
laminator roll. Before pressing this switch to the  
DOWN position, ensure that nothing is in the nip area.  
If any problem or danger should occur, depressing any  
of the emergency buttons stops the rolls from closing  
and raises them completely.  
The following symbols are used throughout this man-  
ual to indicate warnings and cautions.  
DANGER  
Indicates an imminently hazardous situation  
which, if not avoided, will result in death or  
serious injury.  
Note  
To quickly stop the machine in the event of an emer-  
gency, press any of the emergency stop buttons or apply  
force to either kick cable. This action stops the machine  
completely and raises the rolls.  
WARNING  
In addition, the rolls of the ORCA-IV can reach tem-  
peratures of over 290 °F (143 °C). At these tempera-  
tures you can be burned if the rolls are touched during  
set-up, operation or servicing.  
Indicates a potentially hazardous situation  
which, if not avoided, could result in death or  
serious injury.  
Opening any door of the image transfer laminator  
causes the rolls to slow to 3.0 ft/min (1 m/min).  
CAUTION  
Indicates a potentially hazardous situation  
which, if not avoided, could result in minor or  
moderate injury, or alerts against unsafe  
practices, or alerts against actions which could  
damage the product.  
WARNING  
Do not ever attempt to override the safety system  
on the doors of the machine or the kick cables.  
You could get your fingers or arms between the  
rolls when they are turning or in the closed  
position and you could be crushed or severely  
burned.  
IMPORTANT  
Indicates important additional information.  
The machine has a steel cabinet that is bolted closed to  
isolate the electrical and drive system components for  
the safety of the operator. Only a qualified service tech-  
nician should open these cabinets.  
The ORCA-IV Image Transfer Laminator has been  
designed with safety as a primary consideration. How-  
ever, you must become thoroughly familiar with the  
controls, proper operation, proper service procedures,  
and safety features of the image transfer laminator  
before using or servicing the unit.  
© GBC Pro-Tech 1998 October  
1-1  
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Safety  
ORCA-IV Image Transfer Laminator Operation Manual  
The machine is equipped with four emergency stop  
buttons located on either side of the front and back of  
the image transfer laminator. Any of these, if engaged,  
stops the machine. To continue operation, all emer-  
gency stop buttons must be in the out position and you  
must perform the Machine Reset Procedure. See  
“Machine Reset Procedure” on page 1-3.  
FRONT  
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to stop the  
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to resume  
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button pops out  
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PRO-TECH  
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Figure 1-1: Using the Emergency Stop Buttons  
BACK  
In addition, the ORCA-IV is equipped with two emer-  
gency stop kick cables located at the lower front and  
back of the image transfer laminator.  
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Figure 1-2: Using the Emergency Stop Kick  
Cables  
Either of these, if stepped on or kicked, stops the lami-  
nator and raises the rolls. To continue operation, press  
the kick cable reset button. Then complete the Machine  
Reset Procedure. See “Machine Reset Procedure” on  
page 1-3.  
1-2  
© GBC Pro-Tech 1998 October  
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ORCA-IV Image Transfer Laminator Operation Manual  
Safety  
Kick Cable  
Reset Button  
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Power  
Switch  
w/ Lock  
PRO-TECH  
Reset  
Button  
Figure 1-3: Kick Cable Reset Button  
Machine Reset Procedure  
W
ARNING  
ACHTUNG  
MISE EN GARDE  
Power  
Switch/  
Lockout  
Perform this procedure whenever an emergency stop  
button or kick cable is activated or when the power to  
the machine is turned on.  
POWER  
1. Make sure all emergency stop buttons and kick  
cables are reset.  
2. Press the main machine reset button above the  
power switch on the back of the machine. See Fig-  
ure 1-4: Machine Reset Button.  
Figure 1-4: Machine Reset Button  
Despite the safety features built into the ORCA-IV,  
extreme caution must be used when operating or ser-  
vicing the unit. READ THE FOLLOWING WARN-  
INGS AND CAUTIONS BEFORE ATTEMPTING  
TO OPERATE OR SERVICE THE ORCA-IV  
IMAGE TRANSFER LAMINATOR.  
3. Check the web force settings to make sure they are  
what you require.  
4. Turn the heater back on. It is necessary to restart  
the heater as all power is turned off when an emer-  
gency stop button or kick cable is activated.  
5. Lock the shafts by closing the doors of the machine  
and pressing either the shaft locking switch or the  
FWD or REV arrow.  
WARNING  
6. Start the motor and increase the speed.  
Secure long hair so that it cannot get caught in  
the machinery. Do not wear ties, loose fitting  
clothing or dangling jewelry while cleaning or  
servicing the image transfer laminator. These  
items can get caught in the nip and choke you or  
you can be crushed or burned.  
Note  
If the display does not have a decimal point in it, the  
machine needs to be reset.  
IMPORTANT  
Use a lift to load and unload rolls larger than 50  
yards. They can weigh up to 500 lbs and can  
crush you.  
© GBC Pro-Tech 1998 October  
1-3  
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Safety  
ORCA-IV Image Transfer Laminator Operation Manual  
IMPORTANT  
IMPORTANT  
Do not operate the image transfer laminator near  
water. You can be severely shocked, electrocuted  
or cause a fire.  
Raise the upper main roll when the image  
transfer laminator is not in operation. Prolonged  
contact can damage the rolls.  
DANGER  
IMPORTANT  
Remove and lockout power from the image  
transfer laminator before servicing. You can be  
severely shocked, electrocuted or cause a fire.  
Do not leave the top roll heater on with the roll  
raised. Heat builds up in a stationary roll and can  
damage it.  
IMPORTANT  
IMPORTANT  
Do not use liquid or aerosol cleaners on the image  
transfer laminator. Do not spill liquid of any kind  
on the image transfer laminator. You can be  
severely shocked, electrocuted or cause a fire. Use  
only a damp cloth for cleaning.  
Excess pressure can damage the rolls. Always  
select the minimum roll pressure necessary to  
complete the task.  
IMPORTANT  
If silicone adhesive contacts the upper or lower  
roll, remove it IMMEDIATELY using 80 %  
isopropyl alcohol. It can harden within an hour  
and ruin the roll.  
IMPORTANT  
Use only 80% (or stronger) isopropyl alcohol or a  
rubber cement eraser to clean the rolls. Harsh  
chemicals like toluene, acetone or MEK destroy  
the silicone covering of the rolls.  
IMPORTANT  
The operating environment must be free of dust,  
flammable liquids and vapors. You can be  
injured by inhaling chemical vapors. Vapor build  
up or stored flammable liquids can cause a fire.  
Excessive dust can damage the image transfer  
laminator.  
IMPORTANT  
Exercise care when cleaning the rolls with  
80% (or stronger) isopropyl alcohol:  
Use only in a well ventilated area.  
Wear rubber gloves.  
Use only on cool rolls.  
IMPORTANT  
Cleaning heated rolls can ignite the fumes.  
Do not use a knife or other sharp instrument  
during installation or while servicing the image  
transfer laminator. You can cause irreparable  
damage to the rolls.  
1-4  
© GBC Pro-Tech 1998 October  
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ORCA-IV Image Transfer Laminator Operation Manual  
Safety  
IMPORTANT  
IMPORTANT  
Do not attempt to move the image transfer  
laminator across anything other than a flat, level  
surface without trained and qualified riggers.  
You can be crushed or seriously injured.  
Do not open the side covers of the machine. Only  
a qualified service technician should remove the  
covers. You can be severely shocked,  
electrocuted, or crushed.  
The ORCA-IV Image Transfer Laminator is a  
large and heavy piece of equipment. It is  
necessary to employ LICENSED RIGGERS  
ONLY to move the machine. The image transfer  
laminator is not designed to be tipped up or  
sideways in any way. Such action disturbs the  
exact alignment of the rolling parts of the  
machine and requires extensive realignment.  
GBC Pro-Tech’s warranty does not cover  
malfunction of the equipment due to mishandling  
and/or tipping.  
IMPORTANT  
Never operate the machine with side covers open.  
You can be severely shocked, electrocuted, or  
crushed.  
ALWAYS USE GOOD SAFETY PRACTICES  
WHEN OPERATING OR SERVICING THE IMAGE  
TRANSFER LAMINATOR AND KNOW HOW TO  
REACT QUICKLY IN AN EMERGENCY.  
GBC Pro-Tech bears no responsibility for  
personal injury or damage due to moving the  
image transfer laminator improperly.  
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On your ORCA-IV Image Transfer Laminator are  
important safety labels. See Figure 1-5: Locations of  
Safety Labels for the location of these labels.  
WARNING  
Only a qualified electrician should connect power  
to the image transfer laminator. You can be  
severely shocked, electrocuted or cause a fire if  
power is improperly applied.  
IMPORTANT  
Do not operate the image transfer laminator if  
the power cord is damaged or frayed. You can be  
severely shocked, electrocuted or cause a fire.  
Contact a qualified electrician to replace the  
cord.  
IMPORTANT  
Do not allow anything to rest on the power cord.  
Do not locate the cord where people can walk on  
it. You or others can be severely shocked,  
electrocuted or cause a fire.  
© GBC Pro-Tech 1998 October  
1-5  
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Safety  
ORCA-IV Image Transfer Laminator Operation Manual  
Located  
WARNING  
One Located At  
Each Roll Load  
Point (7 Total)  
Inside  
ACHTUNG  
Cabinet  
MISE EN GARDE  
Located  
Inside  
Cabinet  
CAUTION! EXPOSED ROLLER  
Can cause personal injury.  
Keep hands, long hair, ties, jewelry  
and loose clothing away from this area.  
Located Inside  
Cabinet  
©1994 Hazard Communication Systems, Inc. 800-748-0241  
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©1994 Hazard Communication Systems, Inc. 800-748-0241  
P
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MISE EN GARDE  
MISE EN GARDE  
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E
N
C
Y
G
S
R
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O
E
M
P
Emer  
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E
A
R
g
enc  
or Step on to Stop Laminating Pr  
R
E
k
y
Stop Kic  
T
T
'
U
k
Cab  
les Located Belo  
R
E
G
C N E  
24VDC  
6
1
A/250V 1/4  
A/250V 1/4  
X
X
1-1/4 IN  
1-1/4 IN  
[
[
5
5
X
X
20mm  
20mm  
]
]
psi  
w
100  
ocess..  
90  
80  
70  
60  
50  
40  
30  
20  
10  
kPa  
700  
630  
560  
490  
420  
350  
280  
210  
140  
70  
CAUTION  
FOR CONTINUED PROTECTION AGAINST RISK OF FIRE,  
REPLACE ONL WITH SAME TYPE AND RATING OF FUSE  
IV™  
CA  
L
3200  
Y
ORCA  
CAL  
320  
0
Located Inside  
Cabinet  
®
LIST.EED  
I.T  
4
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0
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1
2
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On  
.  
UCTIONS  
THE  
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ALLA  
CONNECTING  
...  
T
SEE INST  
Y
BEFORE  
Exterior  
SUPPL  
SAFETY  
INSTR  
SICHEURCHTEIIOTSN-S  
RICHTLINIEN  
Located Inside  
Cabinet  
CONSIGNES DE  
SÉCURITÉ  
Panels  
HIGH LEAKAGE CURRENT!  
Earth connection essential before  
connecting supply  
PRO-TECH  
®
SEE INSTALLATION INSTRUCTIONS  
BEFORE CONNECTING TO THE  
SUPPLY  
LISTED  
I.T.E  
6N10  
Model No.  
Serial No.  
VAC  
Hz  
®
Amps  
Phase  
Wires  
Emergency Stop Kick Cables Located Below.  
Kick or Step on to Stop Laminating Process.  
MADE IN U.S.A.  
Located On Door  
SAFETY  
INSTRUCTIONS  
100 PSI  
700 KPa  
©1997 HCS, Inc. 800-748-0241 No. 6101-52BVPK  
SICHERHEITS-  
RICHTLINIEN  
CONSIGNES DE  
SÉCURITÉ  
Figure 1-5: Locations of Safety Labels  
1-6  
© GBC Pro-Tech 1998 October  
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ORCA-IV Image Transfer Laminator Operation Manual  
Safety  
The following are typical safety hazard decals used on GBC Pro-Tech machines, with a brief description (“Mean-  
ing” column) of each decal.  
Decal  
Meaning  
Decal  
Meaning  
WARNING!  
WARNING!  
WARNING  
ACHTUNG  
MISE EN GARDE  
SAFETY  
INSTRUCTIONS  
Moving parts can  
crush and cut.  
1. Read and understand the Operation Manual and  
all safety labels before operating this machine.  
2. Only a trained person is to be permitted to operate  
this machine. Training should include instruction  
in operation under normal conditions and  
emergency situations.  
3. This machine is to be serviced only by trained and  
authorized personnel. Follow lockout procedures  
before servicing.  
SICHERHEITS-  
RICHTLINIEN  
Do not operate with  
guard or door open.  
CONSIGNES DE  
SÉCURITÉ  
4. Never reach into the machine for any reason unless  
the machine is at a COMPLETE STOP.  
5. Never leave the machine stopped in such a manner  
that another worker can start the machine while  
you are working on or within the machine.  
6. Never change or defeat the function of electrical  
interlocks or other machine "shutdown" switches.  
7. Before starting this machine, check that:  
- All persons are clear of the machine.  
- No maintenance work is being performed on  
the machine.  
WARNING!  
WARNING  
WARNING  
ACHTUNG  
MISE EN GARDE  
Crush and burn  
ACHTUNG  
hazard. Stay clear of  
moving rollers. Stop  
machine and raise roll  
before cleaning.  
MISE EN GARDE  
or  
- All guards are in place.  
- All parent rolls are well chucked in the unwind  
stands.  
- The machine is free of paper scraps, wraps and  
jams.  
WARNING!  
WARNING  
ACHTUNG  
MISE EN GARDE  
Carefully read  
8. There is a potential hazard of entanglement in this  
machine caused by items such as long hair, loose  
clothing, and jewelry. Make sure your clothing and  
hair fit closely to your body and that all jewelry,  
rings and watches are removed.  
Operator's Manual  
before handling this  
machine. Observe  
instructions and safety  
rules when operating.  
CAUTION!  
Air pressure must be less than 100 PSI (700 kPa) to  
avoid damaging the machine.  
WARNING!  
100 PSI  
HAZARDOUS  
VOLTAGE.  
700 KPa  
©1997 HCS, Inc. 800-748-0241 No. 6101-52BVPK  
or  
To be serviced only by  
trained and authorized  
personnel.  
Reset.  
©1994 Hazard Communication Systems, Inc. 800-748-0241  
Lockout power before  
servicing.  
WARNING!  
C
CAUTION!  
Surface is hot.  
EMERGENCY STOP BUTTON  
Press this button to stop the machine cycle, remove  
electric power, and separate (open) rolls to eliminate a  
pinch point (on some machines).  
or  
T
C
O
A burn hazard exists.  
Electric power disconnect and lock out location.  
CAUTION!  
CAUTION!  
Rolls are heavy.  
Use proper lifting  
techniques to prevent  
injury.  
CAUTION! EXPOSED ROLLER  
Can cause personal injury.  
Keep hands, long hair, ties, jewelry  
and loose clothing away from this area.  
EXPOSED ROLLER  
Can cause personal injury. Keep hands, long hair, ties,  
jewelry and loose clothing away from this area.  
Emergency Stop Kick Cables Located Below.  
Kick or Step on to Stop Laminating Process.  
Emergency Stop Kick Cables Located Below. Kick or  
Step on to Stop Laminating Process.  
CAUTION!  
SEE INSTALLATION INSTRUCTIONS  
BEFORE CONNECTING TO THE  
SUPPLY  
SEE INSTALLATION INSTRUCTIONS BEFORE  
CONNECTINGTOTHE SUPPLY.  
For continued  
protection against risk  
of fire, replace only with  
same type and rating  
of fuse.  
6
A
1
A
6
A
HIGH LEAKAGE CURRENT!  
Earth connection essential before  
connecting supply  
HIGH LEAKAGE CURRENT!  
Earth connection essential before connecting supply.  
24VDC  
6
1
A/250V 1/4  
A/250V 1/4  
X
X
1-1/4 IN  
1-1/4 IN  
[
[
5
5
X
X
20mm  
20mm  
]
]
CAUTION  
FOR CONTINUED PROTECTION AGAINST RISK OF FIRE,  
REPLACE ONL WITH SAME TYPE AND RATING OF FUSE  
Y
Earth ground.  
Machine identification  
label.  
®
LISTED  
I.T.E  
6N10  
Model No.  
Serial No.  
VAC  
Hz  
®
Amps  
Phase  
Wires  
MADE IN U.S.A.  
© GBC Pro-Tech 1998 October  
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Safety  
ORCA-IV Image Transfer Laminator Operation Manual  
Blank page.  
1-8  
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ORCA-IV Image Transfer Laminator Operation Manual  
Installation  
6HFWLRQꢁꢅꢁꢃꢁ,QVWDOODWLRQ  
GBC Pro-Tech is committed to a program of ongoing  
product improvement. As a result, we are providing  
these instructions so that you can ensure that your new  
ORCA-IV Laminator is properly and securely  
unpacked, moved and installed.  
IMPORTANT  
The operating environment must be free of dust,  
flammable liquids and vapors. You can be  
injured by inhaling chemical vapors. Vapor build  
up or stored flammable liquids can cause a fire.  
Excessive dust can damage the image transfer  
laminator.  
Before an ORCA-IV Image Transfer Laminator can be  
installed there are a few requirements that must be met.  
Make certain that each of the requirements listed in the  
following preinstallation checklist are met before  
beginning installation.  
IMPORTANT  
Do not locate the image transfer laminator where  
air is blowing directly on the machine. The air  
flow can cool the rolls unevenly and result in poor  
quality output.  
IMPORTANT  
Failure to follow the preinstallation checklist can  
result in damage to the image transfer laminator.  
Have you contacted a certified electrician to both  
hard wire the laminator and ensure that an adequate  
power supply, having the appropriate capacity,  
overcurrent protection, and safety lockouts is avail-  
able?  
3UHLQVWDOODWLRQꢁ&KHFNOLVW  
Are doorways and hallways wide enough for the  
image transfer laminator to be moved to the instal-  
lation site?  
The laminator requires 4 wire North American  
Delta 230 VAC, 50/60 Hz, three phase, 45A per  
phase with the preheater option and 35A per phase  
without the preheater option.  
Is there ample room for the image transfer lamina-  
tor?  
A work area must be established that allows for  
operation in both the front and the rear of the  
machine and provides space for efficient material  
flow. See Figure 2-6: Machine Space Require-  
ments for a typical machine area layout.  
Note  
If you require setup for European power input (three  
phase wye), please contact GBC Technical Support.  
Is the environment appropriate for the image trans-  
fer laminator?  
The image transfer laminator requires a clean, dust  
and vapor free environment to operate properly,  
such as an air conditioned office area with forced  
10% make up air. However, the image transfer lam-  
inator must not be located where there is air blow-  
ing directly on it. Major fluctuation in temperature  
and humidity are to be avoided.  
CAUTION  
Do not ever attempt to change the internal  
jumper configurations. Only a qualified GBC  
Service Technician can change these  
configurations. You can severely damage the  
machine.  
© GBC Pro-Tech 1998 October  
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Installation  
ORCA-IV Image Transfer Laminator Operation Manual  
Is there an appropriate filtered dry air supply avail-  
able?  
The machine requires filtered dry air at 1.5 cubic  
feet per minute (cfm), 50 liters/minute at a pressure  
of 100 pounds per square inch (psi) (700 kPa). The  
air supply must be clean (free of dirt) and dry.  
Moisture causes corrosion and particles block  
pneumatic controls. Either problem can cause the  
laminator to malfunction.  
It is the customer's responsibility to provide appro-  
priate filters and water traps for the air hose before  
the air is routed to the laminator. Pro-Tech suggests  
that the best approach to the air requirement is to  
provide a dedicated small compressor for the lami-  
nator. A standard light-duty ½ to ¾ horse power (1  
kW) electric air compressor with 1.5 to 2.5 cfm  
output with a 5 gallon (20 liter) storage tank is  
appropriate.  
IMPORTANT  
The air supply to the laminator must be clean  
and dry or the machine will be damaged.  
2-2  
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ORCA-IV Image Transfer Laminator Operation Manual  
Installation  
4' x 6'  
(1.2m x 2m)  
Work Table  
on Wheels  
Rear  
Electrical  
Supply  
38.4"  
(.98m)  
(Standard  
Inlet on  
Bottom of  
Machine)  
50"  
(1.27m)  
Air Supply  
24'  
(7.3m)  
(On Bottom of  
Machine)  
85" (2.16m)  
Front  
4' x 6'  
(1.2m x 2m)  
Work Table  
on Wheels  
20' (6m)  
Figure 2-6: Machine Space Requirements  
© GBC Pro-Tech 1998 October  
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Installation  
ORCA-IV Image Transfer Laminator Operation Manual  
8. Gently unwrap the shrink wrap from around the  
image transfer laminator and remove the foam pro-  
tecting the corners of the machine.  
8QSDFNLQJ  
NOTE  
ALL SHIPMENTS ARE EX- WORKS. At our dock title  
passes to the buyer Please review your insurance cov-  
erage prior to shipment, as you are responsible for all  
subsequent freight charges and risks. Before signing  
the Bill of Lading you should be sure to inspect the  
machine for signs of damage or missing items; if appli-  
cable, you should make a note of this on the Bill of Lad-  
ing.  
IMPORTANT  
Do not use a knife or other sharp instrument  
during installation or while servicing the image  
transfer laminator. You can cause irreparable  
damage to the rolls.  
The ORCA-IV Image Transfer Laminator is shipped  
encased in shrink wrap via Air Ride Van.  
9. Carefully remove any accessories packed with the  
machine. The accessory pack should contain:  
To unpack the machine:  
1 Towel, white  
1 Slitting knife  
7. Have the image transfer laminator rolled off the  
Air Ride Van and placed on the floor by licensed  
riggers.  
1 Set, hex wrenches  
4 Leveling pads  
3 Fuses (6A, 250V)  
1 Tape measure  
1 Rubber cement pick-up  
1 Strain relief  
IMPORTANT  
Do not attempt to move the image transfer  
laminator across anything other than a flat, level  
surface without trained and qualified riggers.  
You can be crushed or seriously injured.  
1 Manual  
4 Slitter Assemblies  
1
2 T-handle wrenches ( / ")  
4
2 Web unwind spacers  
The ORCA-IV Image Transfer Laminator is a  
large and heavy piece of equipment. It is  
necessary to employ LICENSED RIGGERS  
ONLY to move the machine. The image transfer  
laminator is not designed to be tipped up or  
sideways in any way. Such action disturbs the  
exact alignment of the rolling parts of the  
machine and requires extensive realignment.  
GBC Pro-Tech’s warranty does not cover  
malfunction of the equipment due to mishandling  
and/or tipping.  
10. Remove any plastic strapping and packing paper  
taped to the rolls.  
IMPORTANT  
Do not use a knife or other sharp instrument  
during installation or while servicing the image  
transfer laminator. You can cause irreparable  
damage to the rolls.  
GBC Pro-Tech bears no responsibility for  
personal injury or damage due to moving the  
image transfer laminator improperly.  
11. Remove all packing materials to a safe distance  
from the image transfer laminator.  
12. Level the machine using the procedure included in  
this section.  
2-4  
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ORCA-IV Image Transfer Laminator Operation Manual  
Installation  
NOTE  
/HYHOLQJ  
A word about international shipments: As these are  
heavy pieces of equipment, GBC Pro-Tech takes every  
precaution to ensure that our image transfer lamina-  
tors are properly crated to the highest standards.  
Tools required:  
Adjustable wrench  
Carpenter's level (or equivalent)  
Before machines leave our loading dock, they are pre-  
treated with a VCI protective film to provide total cor-  
rosion protection. This protective film is wrapped  
around the machine and completely sealed. In addition,  
moisture absorbing silicone desiccant packs are  
packed inside the crate and machine cabinets.  
To level the laminator:  
1. Install the four level pads (included in the acces-  
sory pack) on the ends of the foot bolts.  
2. Remove the rear idler so that you can place a car-  
petner’s level across the pull roll to the bottom  
main roll.  
Prior to start up of the machine, you must remove the  
desiccant packs from each cabinet and discard. DO  
NOT operate the machine with the desiccant packs  
inside the cabinets.  
6HWXS  
Once the ORCA-IV Image Transfer Laminator has  
been unpacked and moved into final position perform  
the following setup procedure.  
Tools required:  
1
/ " hex wrench  
8
Adjustable wrench  
Setup Procedure  
1. Inspect the machine for any obvious shipping dam-  
age.  
Figure 2-7: Leveling Front to Rear  
3. Level this side of the machine front to rear, raising  
or lowering the leveling pads by adjusting the nuts  
on the foot bolts.  
2. Remove the drive and control side cabinet covers  
1
with the / " hex wrench by removing the screws  
8
securing the covers to the machine. Lift the covers  
off.  
4. Move the level to the other side of the machine and  
level front to rear.  
3. Inspect all the bolts and tighten any that were loos-  
ened during shipping.  
5. Place the level directly on the chrome tie bar below  
the pull rolls and level the back of the machine side  
to side.  
4. Have a certified electrician wire the machine  
directly to a power source.  
5. Connect the machine to the air supply.  
6. Replace all cabinet covers.  
© GBC Pro-Tech 1998 October  
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Installation  
ORCA-IV Image Transfer Laminator Operation Manual  
6WDUWXS  
The first time the image transfer laminator is started  
and every time it is serviced you should use the follow-  
ing checklist to confirm that the unit is operating prop-  
erly and that all safety mechanisms are functioning.  
Startup Checklist  
Start the image transfer laminator and go through the  
following checklist.  
Are the emergency stop buttons working?  
Push down on one of the emergency stop buttons.  
The image transfer laminator should stop immedi-  
ately. Reset the button by turning it clockwise until  
it pops up. Press the reset button. See Figure 1-4:  
Machine Reset Button to locate the main machine  
reset button. Start the laminator. The machine  
Figure 2-8: Leveling Side to Side  
6. Place the level directly on the chrome tie bar in the  
front of the machine and level the front of the  
machine side to side.  
should resume operation. Always check all four  
buttons.  
7. Recheck the front to rear level condition to ensure  
that it has not changed. If it has, repeat the leveling  
procedure.  
IMPORTANT  
Never operate the image transfer laminator  
unless all of the emergency stop buttons are  
functioning properly. You can be crushed or  
burned.  
8. Remove the four metal casters after the machine is  
leveled (casters provided for transportation only).  
Are the emergency stop kick cables working?  
With the laminator running, step on or kick the  
front emergency stop kick cable. The rolls should  
stop turning and rise, if they are lowered. Reset the  
kick cable button. See Figure 1-3: Kick Cable  
Reset Button to locate the kick cable reset button.  
Then reset the main machine reset. See Figure 1-4:  
Machine Reset Button to locate the main machine  
reset button.  
IMPORTANT  
Never operate the image transfer laminator  
unless both of the emergency stop kick cables are  
functioning properly. You can be crushed or  
burned.  
2-6  
© GBC Pro-Tech 1998 October  
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ORCA-IV Image Transfer Laminator Operation Manual  
Installation  
Is the safety system on the doors functioning.  
Open any door of the image transfer laminator. The  
rolls should slow to 3.0 ft/min (1 m/min) with the  
CAUTION  
doors open. You should not be able to increase the  
speed of the machine above 3.0 ft/min (1 m/min).  
Never allow loose objects (pens, knife blades,  
jewelry, etc.) close to the machine or web paths.  
These objects can fall onto the web and can be  
carried through to the roll. Severe roll damage  
can occur.  
Note  
The speed control works best with a slow, gradual  
increase or decrease of the speed control knob.  
Once you have completed the startup checklist you can  
safely run a test sample.  
IMPORTANT  
Never operate the image transfer laminator  
unless safety system on the doors is functioning  
properly. You can be crushed or burned.  
Is the motor functioning?  
Test the motor at various speeds ranging from  
0-19 ft/min (0-5.8 m/min). At 0 the rolls should  
stop turning.  
Run the motor in both forward and reverse. In  
reverse you should hear a beep once a second to  
alert you that you are operating the machine in  
reverse.  
Are the heaters working?  
Verify that the heater controller heats the top roll.  
(The bottom roll cannot be heated.)  
Is the temperature set correctly?  
Check that the temperature is set to 290°F  
(143.3 °C) for most transfer processes.  
IMPORTANT  
Never allow any film, packing material, object,  
etc. to block the infrared temperature sensor. The  
sensor has a cone-shaped view of the roll that  
should never be obstructed. Severe roll damage  
can occur.  
© GBC Pro-Tech 1998 October  
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Installation  
ORCA-IV Image Transfer Laminator Operation Manual  
Blank page.  
2-8  
© GBC Pro-Tech 1998 October  
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ORCA-IV Image Transfer Laminator Operation Manual  
Operation  
6HFWLRQꢁꢆꢁꢃꢁ2SHUDWLRQ  
WARNING  
6DIHW\  
Do not ever attempt to override the safety system  
on the doors of the machine or the kick cables.  
You could get your fingers or arms between the  
rolls when they are turning or in the closed  
position and you could be crushed or severely  
burned.  
The ORCA-IV Image Transfer Laminator has been  
designed with safety as a primary consideration. How-  
ever, you must become thoroughly familiar with the  
controls, proper operation, proper service procedures,  
and safety features of the image transfer laminator  
before using or servicing the unit.  
The GBC Pro-Tech ORCA-IV is a powerful machine  
that is designed for vinyl transfer and over-lamination.  
The forces required to accomplish these tasks are very  
large.  
The machine has a steel cabinet that is bolted closed to  
isolate the electrical and drive system components for  
the safety of the operator. Only a qualified service tech-  
nician should open these cabinets.  
The air-cylinder system used to provide downward  
pressure on the top roll is capable of producing forces  
greater than 1000 pounds (454kg). This force is applied  
to any object presented in the opening (called the nip)  
between the two rolls.  
Use care in lowering the top main roll and know how to  
react quickly in an emergency. The laminator roll UP-  
DOWN switch is located on the instrument panels.  
This switch controls the up and down motion of the top  
laminator roll. Before pressing this switch to the  
DOWN position, ensure that nothing is in the nip area.  
If any problem or danger should occur, depressing any  
of the emergency buttons stops the rolls from closing  
and raises them completely.  
Note  
To quickly stop the machine in the event of an emer-  
gency, press any of the emergency stop buttons or apply  
force to either kick cable. This action stops the machine  
completely and raises the rolls.  
In addition, the rolls of the ORCA-IV can reach tem-  
peratures of over 290 °F (143 °C). At these tempera-  
tures there is a danger of a severe burn if the rolls are  
touched during set-up, operation or servicing.  
Opening any door of the image transfer laminator  
causes the rolls to slow to 3.0 ft/min (1 m/min).  
© GBC Pro-Tech 1998 October  
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Operation  
ORCA-IV Image Transfer Laminator Operation Manual  
The machine is equipped with four emergency stop  
buttons located on either side of the front and back of  
the image transfer laminator. Any of these, if engaged,  
stops the machine. To continue operation, all emer-  
gency stop buttons must be in the up position and you  
must perform the Machine Reset Procedure. See  
“Machine Reset Procedure” on page 3-3.  
FRONT  
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P
R
R
O
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60  
50  
40  
60  
50  
40  
60  
50  
40  
60  
50  
40  
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0  
0  
0  
42
35
Push any button  
to stop the  
Twist each button  
to resume  
operation - the  
button pops out  
IV™  
ORCA  
0
0
0
laminator  
PRO-TECH  
Emergency  
Stop Kick  
Cable  
E
S
E
S
M
M
E
E
E
C
E
C
R
R
N
N
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G
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T
T
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E
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O P  
R
R
R
A
A
Figure 3-1: Using the Emergency Stop Buttons  
BACK  
In addition, the ORCA-IV is equipped with two emer-  
gency stop kick cables located at the lower front and  
back of the image transfer laminator.  
R
E
M
E
R
R
E
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psi  
IV™  
100  
©9  
90  
80  
70  
60  
50  
40  
30  
20  
10  
kPa  
700  
630  
560  
490  
420  
350  
280  
210  
140  
70  
,
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r
.0
-
i  
ORCA  
PRO  
-TE  
CH  
0
0
2
3
PRO-TECH  
Emergency  
Stop Kick  
Cable  
Figure 3-2: Using the Emergency Stop Kick  
Cables  
Either of these, if stepped on or kicked, stops the lami-  
nator and raises the rolls. To continue operation, press  
the kick cable reset button. Then complete the Machine  
Reset Procedure. See “Machine Reset Procedure” on  
page 3-3.  
3-2  
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ORCA-IV Image Transfer Laminator Operation Manual  
Operation  
6. Start the motor and increase the speed.  
Kick Cable  
Reset Button  
N
E
C
Y
G
S
R
E
T
O
E
M
P
A
R
R
E
T
'
U
R
G
E
C
N E  
%
10  
0
90  
80  
70  
60  
50  
40  
30  
20  
10  
%
10  
0
90  
80  
70  
60  
50  
40  
30  
20  
10  
%
10  
0
90  
80  
70  
60  
50  
40  
30  
20  
10  
Power  
Switch  
w/ Lock  
PRO-TECH  
Figure 3-3: Kick Cable Reset Button  
Reset  
Button  
Machine Reset Procedure  
Perform this procedure whenever an emergency stop  
button or kick cable is activated or when the power to  
the machine is turned on.  
W
ARNING  
ACHTUNG  
MISE EN GARDE  
Power  
Switch/  
Lockout  
1. Make sure all emergency stop buttons and kick  
cables are reset.  
POWER  
2. Press the main machine reset button above the  
power switch on the back of the machine. See Fig-  
ure 3-4: Machine Reset Button.  
Figure 3-4: Machine Reset Button  
3. Check the web force settings to make sure they are  
what you require.  
4. Restart the heater if it is being used.  
For your safety, the machine has several audible signals  
that are used to alert you to the status of the machine.  
The following table lists the alert signals.  
5. Lock the shafts by closing the doors of the machine  
and pressing the shaft lock button or starting the  
motor.  
Table 3-1: Audible Signals  
Audible Signal  
Meaning  
Continuous rapid beep  
If the roll is down but  
not turning, the machine  
will begin beeping con-  
tinuously after 10 sec-  
onds.  
Four beeps every 30 sec- If the roll is up and the  
onds after 55 minutes of heater is on, the machine  
inactivity  
will begin beeping four  
times every 30 seconds  
after the machine has  
been inactive for 55  
minutes.  
One beep per second  
The machine is in  
reverse.  
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Operation  
ORCA-IV Image Transfer Laminator Operation Manual  
either a clutch or brake loads that force into the  
internal computer, which then automatically  
2SHUDWRUꢁ&RQWUROV  
The operator controls for the ORCA-IV Image Transfer  
Laminator are located on the front and rear of the  
machine, to the right of the operator positions. The  
names and functions of these controls are as follows:  
adjusts the air pressure sent to the clutch/brake to  
obtain the required web tension based on the roll  
size. When you enter the setting and then turn the  
motor on, the indicator changes from reading the  
web force to the actual pressure sent to the brake to  
attain the required web force calculated for that roll  
size. In Manual Tension mode the display reads  
actual pressure sent to the clutch/brake. This pres-  
sure stays set until you change it. The computer  
will not override your setting or change the display.  
psi  
100  
90  
80  
70  
60  
50  
40  
30  
20  
10  
kPa  
700  
630  
560  
490  
420  
350  
280  
210  
140  
70  
Roll Temperature  
Adjustment/Displa  
8
9
1
CAL 3200  
Main Roll  
Pressure  
Display  
6. SPEED/ACCUMULATOR DISPLAY - Dis-  
plays either the accumulator or speed, depending  
on which you have selected with the SPEED/  
ACCUMULATOR TOGGLE. A letter in the dis-  
play before the speed readout indicates the mode of  
operation:  
Roll Heat  
ON/OFF  
Main Roll  
UP/DOWN  
2
3
10  
11  
Pull Roll  
UP/DOWN  
Main Roll  
Pressure  
Adjustment  
Preheater  
ON/OFF  
(optional)  
4
Cooling Fan  
ON/OFF  
Preheater  
H - Manual mode with the preheater off.  
P - Automatic mode with the preheater on.  
L - Manual mode with the preheater on.  
No letter - Automatic mode with the preheater off.  
The following codes alert you to machine status:  
.0 - The machine is reset and ready to be started.  
8888 - Main power has just been turned on and the  
main reset has not yet been pressed.  
12  
13  
Temperature  
Adjustment/Displa  
(optional)  
CAL 3200  
5
6
Preheater Heat  
ON/OFF  
Accumulator  
Reset  
Speed/  
Accumulator  
Toggle  
PRO-TECH  
GBC Logo  
Automatic/Manual  
Mode Control  
14  
15  
0 0 0 0  
Speed/  
Accumulator  
Display  
1 2 3 4  
16  
7
Motion Control  
FORWARD/  
STOP/REVERSE  
Speed  
Adjustment  
In addition to these codes, if an emergency stop  
button or kick cable is activated, the decimal point  
will no longer be displayed (for example, 3.0 would  
change to 3 0). Simply resetting the emergency stop  
button or kick cable does not change the display.  
You must also press the main machine reset button  
for display to read .0 indicating the machine is  
ready to be started. Note that you must reset the  
emergency stop button or kick cable before press-  
ing the main machine reset or the machine will not  
be reset.  
Figure 3-5: Front Control Panel  
1. MAIN ROLL PRESSURE DISPLAY - Displays  
the air pressure pushing the upper main roll down.  
2. MAIN ROLL UP/DOWN - Sets the upper main  
roll to the up (load) or down (operate) position.  
3. MAIN ROLL PRESSURE CONTROL - Varies  
the air pressure fed to the cylinders that drive the  
upper main roll down.  
4. PREHEATER ON/OFF (optional) - Turns on or  
off the preheater. The preheater mode is indicated  
by a P in the accumulator display.  
7. SPEED ADJUSTMENT - Adjusts the speed of  
the machine from zero to maximum as the control  
is turned clockwise. Adjust the speed control  
slowly for best results.  
5. GBC LOGO AUTOMATIC/MANUAL MODE  
CONTROL - Toggles between Automatic Tension  
and Manual Tension mode. In Automatic Tension  
mode, the system automatically adjusts the brake/  
clutch pressure. In Manual Tension mode the sys-  
tem doesn’t automatically adjust these pressures  
(indicated by an H or L in the accumulator dis-  
play). In the Automatic Tension mode with the  
motor stopped, setting a web force (tension) for  
3-4  
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ORCA-IV Image Transfer Laminator Operation Manual  
Operation  
8. ROLL TEMPERATURE - Provides a readout of  
the temperature of the upper main roll and the set-  
point for the desired temperature adjustment. Press  
the star button on the temperature controller to see  
or change the set point.  
9. ROLL HEAT ON/OFF - Turns the heater control-  
ler for the top roll on or off.  
10. PULL ROLL UP/DOWN - Sets the pull roll to  
the up (load) or down (operate) position.  
11. COOLING FAN ON/OFF - Turns the cooling fan  
on or off. Push once to turn only the cooling idlers  
on, push again to turn only the cooling tubes on,  
push a third time to turn both cooling idlers and  
cooling tubes on, and push a fourth time for all  
cooling off.  
12. PREHEATER AIR TEMPERATURE  
(optional) - Provides a readout of the temperature  
of the air inside the preheater and the set-point for  
the desired temperature.  
13. PREHEATER HEAT ON/OFF - Turns the heater  
controller in the preheater roll on or off.  
14. ACCUMULATOR RESET - Resets the accumu-  
lator.  
15. SPEED/ACCUMULATOR TOGGLE - Toggles  
control between the speed and the accumulator.  
16. MOTION CONTROL FORWARD/STOP/  
REVERSE - Controls the direction of the drive  
system, forward, reverse, or stop.  
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Operation  
ORCA-IV Image Transfer Laminator Operation Manual  
arrow is pressed and the machine starts, the com-  
puter calculates the appropriate pressure to attain  
the required web force based on the roll size. The  
indicator then changes to read the actual air pres-  
sure (in psi) sent to the clutch/brake. If the machine  
is in Manual Tension mode, the indicator reads the  
actual air pressure (in psi) sent to the clutch/brake.  
%
100  
90  
80  
70  
60  
50  
40  
30  
20  
10  
2
3
1
4
Upper Middle Clutc  
Upper Middle  
(Rewind) Pressure  
Clutch (Rewind)  
Percent Web  
Force  
Upper Middle Clutch  
(Rewind) Indicator  
%
100  
90  
80  
70  
60  
50  
40  
30  
20  
10  
5
6
Upper Front Clutch  
(Rewind) Pressure  
Upper Front  
Clutch (Rewind)  
Percent Web  
Force  
Upper Front Clutch  
(Rewind) Indicator  
5. UPPER FRONT CLUTCH (REWIND) PRES-  
SURE - Adjusts the clutch pressure up or down.  
%
100  
90  
80  
70  
60  
50  
40  
30  
20  
10  
8
9
7
Middle Front Brake  
Pressure  
Middle Front Brake  
Percent Web Force  
6. UPPER FRONT CLUTCH (REWIND) INDI-  
CATOR - Indicates that this set of controls is for  
the upper front clutch.  
Middle Front  
Brake Indicator  
%
100  
90  
80  
70  
60  
50  
40  
30  
20  
10  
12  
13  
10  
11  
Unwind/Rewind Shaft  
Locking System ON/OFF  
Lower Front Brake  
Pressure  
PRO-TECH  
Lowerr Front Brake  
Percent Braking  
Force  
Lower Front Brake  
Indicator  
7. MIDDLE FRONT BRAKE PERCENT WEB  
FORCE -Indicates the web force (tension) for this  
brake as a percentage of the total possible tension  
the brake can exert. What the pressure indicator  
displays changes depending upon whether the  
motor is on or off and what mode you are operating  
the machine under. With the motor direction  
arrows off and the machine in Automatic Tension  
mode, the indicator displays the material web ten-  
sion you set. Once the motor arrow is pressed and  
the machine starts, the computer calculates the  
appropriate pressure to attain the required web  
force based on the roll size. The indicator then  
changes to read the actual air pressure (in psi) sent  
to the clutch/brake. If the machine is in Manual  
Tension mode, the indicator reads the actual air  
pressure (in psi) sent to the clutch/brake.  
Figure 3-6: Front Brake Panel  
1. UPPER MIDDLE CLUTCH (REWIND) PER-  
CENT WEB FORCE - Indicates the web force  
(tension) for this clutch as a percentage of the total  
possible tension the clutch can exert. What the  
pressure indicator displays will change depending  
upon whether the motor is on or off and what mode  
you are operating the machine under. With the  
motor direction arrows off and the machine in  
Automatic Tension mode, the indicator displays the  
material web tension you set. Once the motor  
arrow is pressed and the machine starts, the com-  
puter calculates the appropriate pressure to attain  
the required web force based on the roll size. The  
indicator then changes to read the actual air pres-  
sure (in psi) sent to the clutch/brake. If the machine  
is in Manual Tension mode, the indicator reads the  
actual air pressure (in psi) sent to the clutch/brake.  
8. MIDDLE FRONT BRAKE PRESSURE -  
Adjusts the brake pressure up or down.  
9. MIDDLE FRONT BRAKE INDICATOR - Indi-  
cates that this set of controls is for the middle front  
brake.  
2. UPPER MIDDLE CLUTCH (REWIND) PRES-  
SURE - Adjusts the clutch pressure up or down.  
10. UNWIND/REWIND SHAFT LOCKING SYS-  
TEM ON/OFF - Engages/disengages the unwind/  
rewind shaft locking system. The switch disen-  
gages the locking system with the door either open  
or closed with the motor off. The doors must be  
shut to engage the system. If the doors are shut and  
the unwind/rewind shafts are disengaged, pushing  
the motion control engages them automatically.  
Note the color coding on each shaft and the shaft  
loading tray. Unwinds are marked with blue and  
rewinds are marked with red. Always use the cor-  
rect shaft in each loading position.  
3. UPPER MIDDLE CLUTCH (REWIND) INDI-  
CATOR - Indicates that this set of controls is for  
the upper middle clutch.  
4. UPPER FRONT CLUTCH (REWIND) PER-  
CENT WEB FORCE - Indicates the web force  
(tension) for this clutch as a percentage of the total  
possible tension the clutch can exert. What the  
pressure indicator displays changes depending  
upon whether the motor is on or off and what mode  
you are operating the machine under. With the  
motor direction arrows off and the machine in  
Automatic Tension mode, the indicator displays the  
material web tension you set. Once the motor  
3-6  
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ORCA-IV Image Transfer Laminator Operation Manual  
Operation  
11. LOWER FRONT BRAKE PERCENT BRAK-  
ING FORCE - Indicates the web force (tension)  
for this brake as a percentage of the total possible  
tension the brake can exert. What the pressure indi-  
cator displays changes depending upon whether the  
motor is on or off and what mode you are operating  
the machine under. With the motor direction  
arrows off and the machine in Automatic Tension  
mode, the indicator displays the material web ten-  
sion you set. Once the motor arrow is pressed and  
the machine starts, the computer calculates the  
appropriate pressure to attain the required web  
force based on the roll size. The indicator then  
changes to read the actual air pressure (in psi) sent  
to the clutch/brake. If the machine is in Manual  
Tension mode, the indicator reads the actual air  
pressure (in psi) sent to the clutch/brake.  
12. LOWER FRONT BRAKE PRESSURE -  
Adjusts the brake pressure up or down.  
13. LOWER FRONT BRAKE INDICATOR - Indi-  
cates that this set of controls is for the lower front  
brake.  
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Operation  
ORCA-IV Image Transfer Laminator Operation Manual  
5. SPEED/ACCUMULATOR DISPLAY - Dis-  
plays either the accumulator or speed, depending  
on which you have selected with the SPEED/  
ACCUMULATOR TOGGLE. A letter in the dis-  
play before the speed readout indicates the mode of  
Pull Roll Torque  
ON/OFF  
7
8
psi  
100  
90  
80  
70  
60  
50  
40  
30  
20  
10  
psi  
100  
90  
80  
70  
60  
50  
40  
30  
20  
10  
kPa  
700  
630  
560  
490  
420  
350  
280  
210  
140  
70  
kPa  
700  
630  
560  
490  
420  
350  
280  
210  
140  
70  
Roll Pull Force  
Adjustment/Display  
1
Pull Roll  
Pressure  
Display  
operation:  
H - Manual mode with the preheater off.  
P - Automatic mode with the preheater on.  
L - Manual mode with the preheater on.  
No letter - Automatic mode with the preheater off.  
The following codes alert you to machine status:  
.0 - The machine is reset and ready to be started.  
8888 - Main power has just been turned on and the  
main reset has not yet been pressed.  
In addition to these codes, if an emergency stop  
button or kick cable is activated, the decimal point  
will no longer be displayed (for example, 3.0 would  
change to 3 0). Simply resetting the emergency stop  
button or kick cable does not change the display.  
You must also press the main machine reset button  
for display to read .0 indicating the machine is  
ready to be started. Note that you must reset the  
emergency stop button or kick cable before press-  
ing the main machine reset or the machine will not  
be reset.  
Pull Roll  
Main Roll  
UP/DOWN  
9
2
3
UP/DOWN  
10  
Pull Roll  
Pressure  
Adjustment  
Pull Roll Torque  
Adjustment  
11  
Cooling Fan  
ON/OFF  
4
5
PRO-TECH  
GBC Logo  
Automatic/Manual  
Mode Control  
12  
13  
Accumulator  
Reset  
Speed/  
Accumulator  
Toggle  
0 0 0 0  
Speed/  
Accumulator  
Display  
1 2 3 4  
14  
6
Motion Control  
FORWARD/  
STOP/REVERSE  
Speed  
Adjustment  
Figure 3-7: Rear Control Panel  
1. PULL ROLL PRESSURE DISPLAY - Displays  
the air pressure pushing the upper pull roll down.  
2. MAIN ROLL UP/DOWN - Sets the upper main  
roll to the up (load) or down (operate) position.  
3. PULL ROLL PRESSURE CONTROL - Varies  
the air pressure fed to the cylinders that drive the  
upper pull roll down.  
6. SPEED ADJUSTMENT - Adjusts the speed of  
the machine from zero to maximum as the control  
is turned clockwise. Turn control knob slowly for  
best results.  
4. GBC LOGO AUTOMATIC/MANUAL MODE  
CONTROL -Toggles between Automatic Tension  
and Manual Tension mode. In Automatic Tension  
mode, the system automatically adjusts the brake/  
clutch pressure. In Manual Tension mode the sys-  
tem doesn’t automatically adjust these pressures  
(indicated by an H or L in the accumulator dis-  
play). In the Automatic Tension mode with the  
motor stopped, setting a web force (tension) for  
either a clutch or brake loads that force into the  
internal computer, which then automatically  
7. PULL ROLL TORQUE ON/OFF - Allows you  
to turn the pull roll clutch (torque) pressure on or  
off without changing the pressure settings.  
8. PULL ROLL PULL FORCE DISPLAY - Dis-  
plays the air pressure of the clutch (torque or pull  
force).  
9. PULL ROLL UP/DOWN - Sets the pull roll to  
the up (load) or down (operate) position.  
10. PULL ROLL TORQUE CONTROL - Varies the  
air pressure fed to the clutch that drives the lower  
pull roll.  
adjusts the air pressure sent to the clutch/brake to  
obtain the required web tension based on the roll  
size. When you enter the setting and then turn the  
motor on, the indicator changes from reading the  
web force to the actual pressure sent to the brake to  
attain the required web force calculated for that roll  
size. In Manual Tension mode the display reads  
actual pressure sent to the clutch/brake. This pres-  
sure stays set until you change it. The computer  
will not override your setting or change the display.  
11. COOLING FAN ON/OFF - Turns the cooling fan  
on or off. Push once to turn only the cooling idlers  
on, push again to turn only the cooling tubes on,  
push a third time to turn both cooling idlers and  
cooling tubes on, and push a fourth time for all  
cooling off.  
3-8  
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ORCA-IV Image Transfer Laminator Operation Manual  
Operation  
12. ACCUMULATOR RESET - Resets the accumu-  
lator.  
13. SPEED/ACCUMULATOR TOGGLE - Toggles  
control between the speed and the accumulator.  
14. MOTION CONTROL FORWARD/STOP/  
REVERSE - Controls the direction of the drive  
system, forward, reverse, or stop.  
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Operation  
ORCA-IV Image Transfer Laminator Operation Manual  
appropriate pressure to attain the required web  
force based on the roll size. The indicator then  
changes to read the actual air pressure (in psi) sent  
to the clutch/brake. If the machine is in Manual  
Tension mode, the indicator reads the actual air  
pressure (in psi) sent to the clutch/brake. Note that  
this clutch (laminate paper rewind) only operates  
when the pull roll is down.  
%
100  
90  
80  
70  
60  
50  
40  
30  
20  
10  
2
3
1
4
Upper Rear Brake  
Upper Rear Brake  
Pressure  
Percent Web Force  
Upper Rear Brake  
Indicator  
%
100  
90  
80  
70  
60  
50  
40  
30  
20  
10  
5
6
Middle Rear Clutch  
Pressure  
Middle Rear Clutch  
Percent Web Force  
Middle Rear  
Clutch Indicator  
%
100  
90  
80  
70  
60  
50  
40  
30  
20  
10  
5. MIDDLE REAR CLUTCH PRESSURE -  
8
9
7
Lower Rear Clutch  
Pressure  
Lower Rear Clutch  
Percent Web Force  
Adjusts the clutch pressure up or down.  
Lower Rear Clutch  
Indicator  
6. MIDDLE REAR CLUTCH INDICATOR - Indi-  
cates that this set of controls is for the middle rear  
clutch.  
10  
Unwind/Rewind  
Shaft Locking  
System ON/OFF  
PRO-TECH  
7. LOWER REAR CLUTCH PERCENT WEB  
FORCE - Indicates the web force (tension) for this  
clutch as a percentage of the total possible tension  
the clutch can exert. What the pressure indicator  
displays changes depending upon whether the  
motor is on or off and what mode you are operating  
the machine under. With the motor direction  
arrows off and the machine in Automatic Tension  
mode, the indicator displays the material web ten-  
sion you set. Once the motor arrow is pressed and  
the machine starts, the computer calculates the  
appropriate pressure to attain the required web  
force based on the roll size. The indicator then  
changes to read the actual air pressure (in psi) sent  
to the clutch/brake. If the machine is in Manual  
Tension mode, the indicator reads the actual air  
pressure (in psi) sent to the clutch/brake.  
Figure 3-8: Rear Brake Panel  
1. UPPER REAR BRAKE PERCENT WEB  
FORCE - Indicates the web force (tension) for this  
brake as a percentage of the total possible tension  
the brake can exert. What the pressure indicator  
displays changes depending upon whether the  
motor is on or off and what mode you are operating  
the machine under. With the motor direction  
arrows off and the machine in Automatic Tension  
mode, the indicator displays the material web ten-  
sion you set. Once the motor arrow is pressed and  
the machine starts, the computer calculates the  
appropriate pressure to attain the required web  
force based on the roll size. The indicator then  
changes to read the actual air pressure (in psi) sent  
to the clutch/brake. If the machine is in Manual  
Tension mode, the indicator reads the actual air  
pressure (in psi) sent to the clutch/brake.  
8. LOWER REAR CLUTCH PRESSURE -  
Adjusts the clutch pressure up or down.  
2. UPPER REAR BRAKE PRESSURE - Adjusts  
9. LOWER REAR CLUTCH INDICATOR - Indi-  
cates that this set of controls is for the lower rear  
clutch.  
the brake pressure up or down.  
3. UPPER REAR BRAKE INDICATOR - Indicates  
that this set of controls is for the upper rear brake.  
10. UNWIND/REWIND SHAFT LOCKING SYS-  
TEM ON/OFF - Engages/disengages the unwind/  
rewind shaft locking system. The switch disen-  
gages the locking system with the door either open  
or closed with one motor off. The doors must be  
shut to engage the system. If the doors are shut and  
the unwind/rewind shafts are disengaged, pushing  
the motion control engages them automatically.  
Note the color coding on each shaft and the shaft  
loading tray. Unwinds are marked with blue and  
rewinds are marked with red. Always use the cor-  
rect shaft in each loading position.  
4. MIDDLE REAR CLUTCH PERCENT WEB  
FORCE -Indicates the web force (tension) for this  
clutch as a percentage of the total possible tension  
the clutch can exert. What the pressure indicator  
displays changes depending upon whether the  
motor is on or off and what mode you are operating  
the machine under. With the motor direction  
arrows off and the machine in Automatic Tension  
mode, the indicator displays the material web ten-  
sion you set. Once the motor arrow is pressed and  
the machine starts, the computer calculates the  
3-10  
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ORCA-IV Image Transfer Laminator Operation Manual  
Operation  
6HWXS  
+HDWLQJ  
Setup of the ORCA-IV Image Transfer Laminator is  
quick and straightforward when instructions are fol-  
lowed exactly.  
Use the following instructions when heating the upper  
main roll.  
1. Set the heater switch to ON.  
2. Adjust the temperature controller for the desired  
operating temperature using the temperature con-  
troller set point adjustment. To adjust the set point,  
hold the star button down and press the up or down  
arrow on the temperature controller.  
/RDGLQJꢁWKHꢁ)LOP  
IMPORTANT  
Use a lift to load and unload rolls larger than 50  
yards. They can weigh up to 500 lbs and can  
crush you.  
3. Allow the roll to come to temperature. After the  
roll has come up to set temperature, let the rolls run  
together for 5 minutes to produce even heat or you  
can also simply start the process a little slower and  
bring it up to speed as the roll reaches prime oper-  
ating temperature.  
Film is loaded on the appropriate unwinds indicated by  
color coding. Blue shafts and loading trays indicate  
unwinds, red shafts and loading trays indicate rewinds.  
The process of loading and aligning film is the same  
for both the top and the bottom unwinds/rewinds.  
4. The temperature controller has an LED (light emit-  
ting diode) readouts to indicate the status of the  
heating system.  
1. Be sure that rewind (clutch) shafts are in rewind  
positions (loading trays) and unwind (brake) shafts  
are in unwind positions so that the core gripping  
mechanism engages properly.  
5. It will take approximately 45 minutes for the upper  
main roll to reach operating temperature. When the  
preset operating temperature has been reached, the  
machine is ready to use.  
2. Slide the shaft over until the drive tang fits in the  
slot before engaging the unwind/rewind shaft lock-  
ing system.  
3. Loosen the lock collar with a 1/4" hex wrench and  
center the material before webbing the machine.  
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 and other assorted troubles will  
occur. See Table 3-2 for centering and alignment  
information.  
IMPORTANT  
Carefully align the two films being fed into the  
nip. If not, you will obtain poor results.  
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Operation  
ORCA-IV Image Transfer Laminator Operation Manual  
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1. Turn the thumbscrew on the slitter counterclock-  
wise until it stops.  
The ORCA IV image transfer laminator is capable of  
processing a wide range of pressure sensitive and ther-  
mal laminates onto an equally wide range of image  
materials. The primary considerations are:  
Laminate adhesives are compatible with image  
materials.  
The materials properly activate below the maxi-  
mum roll temperature and within the speed and roll  
nip pressure ranges available on the laminator.  
Figure 3-9: Slitter  
It is the operator’s responsibility to ensure the compati-  
bility and operational settings for any laminates/image  
material combination. GBC Pro-Tech Technical Sup-  
port is available at the number provided in the Mainte-  
nance chapter for advice on some material  
combinations.  
2. Turn the thumbscrew one turn clockwise.  
3. Set the slitter blade against the plastic covered  
black roll.  
4. Engage the slitter against the tube by allowing the  
slitter to just touch the tube and then pressing it  
1/16" further.  
Note:  
This machine is designed to do transfer using complete  
systems provided by companies such as GBC Pro-  
Tech, 3M, or Rexam. This system includes the paper,  
inks, vinyl and overlaminate films specifically matched  
to offer excellent performance. Some vinyl materials  
offered by other companies will emit chemicals that  
will cause permanent damage to the rolls.  
Setting the slitter to tight shortens the life of the blade  
and the plastic tube.  
5. Pull the material through the machine to test the  
slitter. Adjust the thumbscrew to obtain the  
required results.  
3DSHUꢁ7LSV  
Always cut the leading edge of a print straight so it  
can be fed perpendicular to the rolls.  
IMPORTANT  
The paper must be trimmed to match the width of  
the vinyl.  
Substituting materials can cause severe damage  
to your machine and is not recommended or  
covered under our warranty.  
The paper will wrinkle if it extends more than 1/2"  
beyond the vinyl edge.  
The trim can be neatly collected by threading it  
behind the imaged transfer media roll and taping it  
to the used transfer media core just to the outside of  
the trimmed transfer media. The diameter of the  
collected trim must be kept the same as the diame-  
ter of the winding transfer media to obtain a good  
quality windup.  
It is the operator’s responsibility to ensure compatibil-  
ity and operational settings for the transfer process.  
Consult your transfer system supplier to ensure the cor-  
rect combinations of materials are being used.  
When trimming the final product, the trim can be  
wound on the same core just outside of the edge of  
the roll.  
3-12  
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ORCA-IV Image Transfer Laminator Operation Manual  
Operation  
10. Load and web the overlaminate as indicated in the  
drawing. The operator has the option of lowering  
the pull roll now or waiting for the image to come  
through.  
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Tools required:  
1
/ " T-handle wrench  
11. Check the web force for all the unwinds and  
rewinds and adjust as necessary.  
4
Tape measure  
12. Lower the main roll and start the motor. Start out at  
a low speed (2-3 ft/min (.6-.9 m/min)) and then  
increase the speed as needed after confirming that  
everything is working well.  
To load film:  
1. Retract the shaft locking plungers and remove the  
shafts.  
2. Slide the shaft into the new roll of material until the  
end plate is tight to the end of the material. Always  
leave the end plate on the drive side locked down.  
This insures that the material alignment will be the  
same from roll to roll. See the material size chart to  
determine what end plate setting to use for differ-  
ent width materials.  
13. Check for looseness at either edge of the paper just  
before it enters the nip. If a loose edge is detected,  
increase the brake 2-5 psi and, if the image is not  
yet into the nip, “pop” the roll up and back down  
quickly to help pull the web straight.  
Note:  
Initial looseness on the edge is common, It is caused by  
one of several things:  
3. Make sure the end plates are tight to the edge of the  
material. If the core protrudes out more than 1/8",  
it will be necessary to use a plastic spacer to fill the  
gap. (Provided in the accessory pack.)  
No tension on the initial web before the roll comes  
down.  
4. Place the roll of material on the machine. Be sure  
to line up with the drive tang and slide the shaft  
over to engage it into the drive tang. Make sure the  
shafts are slid over and engaged. This is critical to  
prevent the material from shifting after the  
machine is webbed.  
Not webbed through perfectly straight.  
Web expansion from the heat as that stays in the  
nip area as the machine is webbed.  
The roll does not come down evenly.  
14. Close the doors and increase the speed as required.  
5. Repeat steps 1 through 4 for the unwinds and  
rewinds.  
15. Observe the machine as it runs the material. Pay  
close attention to the web. Look for loose webs or  
spliced rolls and check the image quality.  
6. When all the material is loaded on the unwinds and  
all the empty cores are loaded on the rewinds, close  
the doors and lock in the shafts.  
IMPORTANT  
7. Open the doors and verify that the paper edge  
matches the edge of the vinyl by measuring from  
the side plate to the edge of the rolls. If the paper or  
vinyl do not match up, loosen the end plates and  
adjust the material so they are exactly in line.  
When the process is complete, stop the machine  
and raise the roll. Do not let either paper or vinyl  
run through the nip alone. The vinyl could stick  
to the roll and the transfer paper would transfer  
to the bottom roll resulting in a large clean up  
job.  
8. Web the vinyl as shown in the diagram and secure  
it to the finished product rewind. For best results,  
align one edge of the rewind core to match the  
material edge measurement on the unwind.  
9. Web the transfer paper and tape it to the front  
rewind as shown in the diagram. If the paper is  
wider than the vinyl, it will be necessary to use the  
slitters to cut the paper down to match the width of  
the vinyl. See “Setting the Slitter” on page 3-12.  
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Operation  
ORCA-IV Image Transfer Laminator Operation Manual  
To advance the vinyl without the paper:  
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Release all the tension on the transfer media web. Start  
the vinyl web. If the paper is not stuck to the vinyl,  
only the vinyl web will advance.  
Table 3-2: Film Spacing  
DistanceFrom DistanceFrom  
End of Shaft  
to Material  
Side Plate  
Machine Side  
to Material  
Side Plate  
Film Size  
The recommended way to change over to new material  
is to splice the new material to the old and let the old  
material web pull the new material through the  
machine.  
54"  
(137.16 cm)  
7-15/16"  
(20.16 cm)  
7-1/2"  
(19.05 cm)  
To splice vinyl:  
When splicing the vinyl, stop the machine before the  
roll is totally used up.  
49"  
(124.46 cm)  
10-7/16"  
(26.51 cm)  
10"  
(25.40 cm)  
1. Load a new roll of vinyl on the unwind shaft and  
place it on the machine. Engage the shaft into the  
drive tang.  
48"  
(121.92 cm)  
10-15/16"  
(27.78 cm)  
10-1/2"  
(26.67 cm)  
2. The old material should be left long enough to lay  
over the new roll. This provides a straight, firm  
surface to splice onto.  
Note  
Always set the drive side and keep it set as the base.  
When changing film, remove the end plate on the con-  
trol side of the shaft. The new roll should then be  
pushed tight up to the plate on the drive side and the  
shaft should be slid over and engaged in the drive.  
3. Tape the new material to the old with a high quality  
1-1/2" to 2" masking or vinyl tape. Make sure the  
materials are straight before applying the tape so  
that one side is not looser than the other.  
4. Start the tape in the center and work outward.  
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5. Lower the brake tension until the splice has cleared  
the main roll.  
Suggested leaders:  
For vinyl: 65" (165.1 cm)  
For paper: 75" (190.5 cm)  
Note  
On machines without the preheater option it is possible  
to splice the two materials together using the bottom  
main roll as the firm, straight taping surface.  
To advance the paper without the vinyl:  
You may want to advance the paper without the vinyl  
for several reasons:  
To splice paper:  
Splicing paper is also the recommended way to change  
over to new material. The key to a successful splice is  
to leave enough of the old paper to be able to wrap it on  
the new roll and tape it on a square, firm surface.  
At the beginning of a new roll to clear the splice  
and reduce leader waste.  
To get past a large white spot, a known extra, or a  
bad image on a roll of images.  
1. Load the new roll of transfer paper on the machine.  
The key to advancing the paper without the vinyl is to  
raise the main roll but let the material continue to run  
through until the paper that is not stuck to the vinyl  
clears the paper peal idler. Then, put the machine in  
reverse briefly to release tension on the paper peal  
idler, or release the pull roll clutch and turn it back by  
hand. Lower the paper unwind and rewind tension and  
hand turn the paper roll so that the paper is advanced  
without the vinyl advancing.  
2. Pull the old paper around the roll of images and  
tension and smooth out evenly.  
3. Overlap the old paper with the new paper and tape  
securely. It is very important to have the new mate-  
rial over the old so that, when the paper is peeled  
off later, the new paper is lifted along with it and  
does not pull the tape off.  
3-14  
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ORCA-IV Image Transfer Laminator Operation Manual  
Operation  
4. Tape starting in the center and move to the sides.  
The tighter and smoother the tape job, the less web  
looseness that will have to be tensioned out later.  
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Process control charts allow you to record the way you  
thread film through the machine's rolls and idlers  
(called webbing) and the control settings for each prod-  
uct and process. Process control charts are an excellent  
tool for training new operators. They provide a "road  
map" for correct machine setup and operation.  
5. Decrease the brake tension until the splice passes  
through the nip. If slitters are being used, be sure  
that they have cut through the two layers of paper  
and the tape at the splice. It is best to run slow as  
the splice passes through the slitters and finish the  
cut, if necessary.  
This section contains a completed chart for the basic  
operation of the image transfer laminator.  
GBC Pro-Tech image transfer laminators respond in a  
very accurate and repeatable manner. The chart pro-  
vides a way to set up each time, every time for repeat-  
able performance by assuring that all controls are set to  
optimum.  
Tape  
New  
Paper  
The process control chart should be kept in this manual  
or in a book close to the image transfer laminator.  
NOTE  
When trying new products and processes, remember  
that GBC Pro-Tech's customer service representatives  
are only a phone call away. In North America, call  
1-608-246-8844 or fax 1-608-246-8645.  
9LQ\Oꢁ7UDQVIHUꢁ  
1. See process chart 3-1 and diagram 3-1a on page  
3-17.  
Figure 3-10: Splicing Paper  
2. Set the controls as follows:  
Main Roll Air Pressure: 100 psi (689 kPa).  
Pull Roll Clutch Air Pressure: 35 psi (241 kPa).  
Pull Roll Up/Down: Down  
Pull Roll Air Pressure: 80 psi (552 kPa).  
Speed Adjust: 1-10 fpm (.3-3.0 m/min).  
Upper Heater Controller: 290 °F (143 °C).  
Cooling: Idlers on, cooling tubes as needed  
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Operation  
ORCA-IV Image Transfer Laminator Operation Manual  
1. See process chart 3-1 and diagram 3-1a for mate-  
rial mounting instructions and machine adjust-  
ments.  
2. Web the vinyl up around the bottom main roll and  
over to the pull roll. Make sure the material is  
webbed straight and lower the pull roll to hold the  
vinyl.  
3. Web the paper through as shown in diagram 3-1a.  
Often, when paper is not on a core, hand tension must  
be applied to the paper in order to maintain transfer  
quality until the end of the transferred image.  
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It is very important that the ORCA-IV Image Transfer  
Laminator is shut down in proper manner. If not, the  
rolls can be damaged or destroyed.  
IMPORTANT  
Failure to follow this procedure can result in  
damage to the rolls.  
1. Raise the upper main roll and upper pull roll so that  
the rolls do not make contact with the bottom rolls.  
2. Turn off the main power to the machine.  
3. Disconnect the air supply to the machine if the  
machine is not to be used for the next several days.  
IMPORTANT  
The main and pull rolls must always be in the up  
position when the machine is not in use.  
3-16  
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ORCA-IV Image Transfer Laminator Operation Manual  
Operation  
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WEB FORCE SUGGESTED VALUES  
Main Product Rewind (Finished Graphic)  
Marking Film (Vinyl) Like 3M (8620, 8640, etc.)  
Used Transfer Media (Rewind)  
20 WF  
20 WF  
20WF  
Transfer Media, 3M 8601i  
15 WF  
50 WF  
30 WF  
Overlaminate Unwind  
Strip Release Liner (Laminate)  
IMAGE TRANSFER LAMINATOR SETTINGS  
Top Heater Status  
290 °F (143 °C)  
Pull Roll Position  
Up or Down (optional unless  
applying laminate)  
Speed  
1-10 fpm (.3-3.0 m/min) max  
Forward  
Main Roll Setting  
Output Cooling  
100 psi (689 kPa)  
Drive Direction  
Drive Mode  
Idlers On, Cooling Tubes Optional  
Automatic or Manual  
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Used  
Transfer  
Media  
Optional  
Paper Trim  
Rewind  
Over-  
laminate  
Imaged  
Transfer  
Media  
Strip  
Release  
Liner  
Cooling  
Tube  
Hot Roll  
Paper  
Peal  
Idler  
Chill  
Idler  
Cooling  
Tube  
Chill  
Idler  
Marking  
Film  
Finished  
Graphic  
Front/Input  
Notes  
__________________________________________________________________________________________  
__________________________________________________________________________________________  
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Operation  
ORCA-IV Image Transfer Laminator Operation Manual  
Blank page.  
3-18  
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ORCA-IV Image Transfer Laminator Operation Manual  
Maintenance and Troubleshooting  
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Tools required:  
Performing regular maintenance on the ORCA-IV  
Image Transfer Laminator is critical to the proper oper-  
ation of the machine. A maintenance schedule and a  
section of procedures for disassembling and reassem-  
bling the serviceable areas of the image transfer lami-  
nator are included in this section.  
80% isopropyl alcohol (or dishwashing detergent)  
Rubber cement eraser  
Several lint free paper or 100% cotton terry cloths  
Protective cotton gloves  
Table 4-3: Maintenance Schedule  
To clean the image transfer laminator rolls:  
Clean the rolls and machine  
1. Open the machine doors and gain access to the  
rolls.  
Daily  
Inspect the area around the image  
transfer laminator for possible haz-  
ards (dust buildup, combustible  
items stored too close, etc.)  
IMPORTANT  
Monthly  
Exercise extreme caution while cleaning the  
image transfer laminator. You can be caught in  
the turning rolls and crushed or burned.  
Lubricate core end plate bolts  
Inspect the roll lift mechanism  
Check the chain tension and lubri-  
cate with heavy motor or gear oil.  
2. While the image transfer laminator is at normal  
operating temperature, put on cotton gloves and,  
using a rubber cement eraser, remove any heat acti-  
vated adhesive from the rolls.  
Lubricate the grease fittings and  
chain  
EverySix  
Months  
Lubricate slitter collar bolts  
Lubricate the roll lift mechanism  
Check wire termination tightness  
IMPORTANT  
Disassemble the roll lift mechanism  
and lubricate with lithium grease  
Yearly  
If silicone adhesive contacts the upper or lower  
roll, remove it IMMEDIATELY using a rubber  
cement eraser. It can harden within an hour and  
ruin the roll.  
IMPORTANT  
Do NOT pick or pull heat activated adhesive off  
the rolls when they are cold. You can cause  
irreparable damage to the laminating rolls.  
IMPORTANT  
Do not use compressed air to clean the machine.  
Blowing debris can be forced into places where it  
will later ignite or short electric circuits.  
© GBC Pro-Tech 1998 October  
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Maintenance and Troubleshooting  
ORCA-IV Image Transfer Laminator Operation Manual  
To clean beads of adhesive, dust and dirt from the  
rolls:  
To clean the cabinet and covers:  
1. Using a damp cotton terry cloth (water only), clean  
the exterior of the image transfer laminator.  
1. Allow the image transfer laminator to cool slightly  
to no higher than 110ºF (43ºC).  
2. Set the FWD/REV switch to the REV position and  
let the rolls move slowly as you clean them. Set the  
Speed Control to 1.5 ft/min.  
WARNING  
Do not use liquid or aerosol cleaners on the image  
transfer laminator. Do not spill liquid of any kind  
on the image transfer laminator. You can be  
severely shocked, electrocuted or cause a fire. Use  
only a damp cloth for cleaning.  
3. Clean the rolls using a moderate amount of 80%  
isopropyl alcohol on a cotton terry cloth.  
IMPORTANT  
To clean the doors:  
Use the minimum amount of pressure necessary  
to clean the rolls. You can destroy the silicone  
layer on the rolls by pressing to hard or  
scrubbing too long in one spot.  
1. Using a cotton terry cloth, wash the doors using a  
mild soap or detergent and lukewarm water.  
IMPORTANT  
IMPORTANT  
Do not scrub or use brushes or squeegees to clean  
the doors. You can scratch the surface.  
Exercise care when cleaning the rolls with 80%  
isopropyl alcohol:  
2. Rinse thoroughly to prevent water spotting.  
3. To remove grease, rub lightly with isopropyl alco-  
hol, then wash and rinse.  
Use only in a well ventilated area.  
Wear rubber gloves.  
Use only on cool rolls.  
Compatible Cleaning Agents:  
Fantastik1  
Cleaning heated rolls can ignite the fumes.  
Formula 4091  
Hexcel, F.O. 554  
Joy2  
Lysol3  
Mr. Clean2  
IMPORTANT  
Use only 80% isopropyl alcohol or a rubber  
cement eraser to clean the laminating rolls.  
Harsh chemicals like toluene, acetone or MEK  
destroy the silicone covering of the rolls.  
Neleco-Placer  
PineSol4  
Top Job2  
1
Windex5  
Registered Trademark of the Clorox Company.  
Registered Trademarks of Procter & Gamble.  
Registered Trademark of Sterling Drugs.  
Registered Trademark of American Cyanamid.  
Registered Trademark of the Drackett Products Company.  
2
3
4
5
4-2  
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ORCA-IV Image Transfer Laminator Operation Manual  
Maintenance and Troubleshooting  
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Occasionally, the kick cable needs adjustment to prop-  
erly reset after use.  
Tools required:  
1
/ " hex wrench  
8
Tools required:  
High temperature grease or lithium grease  
Grease gun  
Phillips head screwdriver  
To adjust the kick cable:  
Heavy weight gear oil  
Soft cloth  
1. Remove the kick cable cover by unscrewing the  
four screws and lifting the cover off.  
2. Check the alignment of the internal mechanism. It  
should seat squarely against the metal pin.  
To lubricate the image transfer laminator:  
IMPORTANT  
Do not lubricate the image transfer laminator  
when it is hot. You can be burned.  
IMPORTANT  
Figure 4-11: Kick Cable Incorrectly Set -  
Mechanism Is Not Square  
Unplug the image transfer laminator and lockout  
power while you are performing this procedure.  
You could be severely shocked, electrocuted, or  
get your fingers caught in the drive mechanisms.  
Mechanism correctly  
seated against metal pin.  
1
1. Remove the drive side cabinet cover using the / "  
8
hex wrench by removing the screws holding the  
cover in place.  
2. Using the grease gun, lubricate each grease fitting  
(shown in Figure 4-1) with one squirt of high tem-  
perature grease.  
3. Grease the main roll lift pins with high temperature  
grease (also shown in Figure 4-1).  
Figure 4-12: Kick Cable Tripped - Mechanism  
Correctly Seated  
4. Using heavy weight gear oil, lubricate the lift  
mechanism. On a yearly basis, disassemble and  
grease all the levers and pins on the lift mecha-  
nism.  
3. The bolts that hold the switch to the bracket are  
slotted and can be used to fine tune the switch  
adjustment. Loosen the bolts, tighten them until  
snug, make the necessary adjustments, then lock  
them down securely.  
5. Lubricate the chain using a soft cloth and gear oil.  
6. Replace the cabinet covers and reconnect power to  
the image transfer laminator.  
Note  
Disassembly of the laminator should be performed by a  
qualified service technician.  
© GBC Pro-Tech 1998 October  
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Maintenance and Troubleshooting  
ORCA-IV Image Transfer Laminator Operation Manual  
&RQWDFWLQJꢁ7HFKQLFDOꢁ6XSSRUW  
For machine parts and technical service in North  
America, please call: 1-608-246-8844 or fax 1-608-  
246-8645. Please provide serial number when call-  
ing for service. In Europe, please call: +44 (0) 1844  
202 440 or fax: +44 (0) 1844 202 441.  
For film and application questions in North America,  
please call 1-608-246-8844 or fax 1-608-246-8645. In  
Europe, please call: +44 (0) 1844 202 440 or fax: +44  
(0) 1844 202 441.  
4-4  
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ORCA-IV Image Transfer Laminator Operation Manual  
Maintenance and Troubleshooting  
Grease Fitting  
Grease Fitting  
Grease Fitting  
Keep Pins (3) Well Oiled (Monthly)  
Disassemble and Grease (Yearly)  
Lubricate Slides with  
Grease  
Pull Roll -  
Grease Both  
Sides, Bottom  
Roll  
Grease Main  
Roll Bearings -  
Both Sides,  
Top and  
Grease Fitting  
Bottom Rolls  
Grease Fitting  
Figure 4-1: Grease Fittings  
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Maintenance and Troubleshooting  
ORCA-IV Image Transfer Laminator Operation Manual  
2XWSXWꢁ7URXEOHVKRRWLQJꢁ*XLGH  
Problem:  
Problem:  
Problem:  
D waves in the image, not in the D waves in the laminate.  
Straight waves in the output.  
laminate.  
Hints:  
Hints:  
Hints:  
• Increase brake tension  
on laminate.  
• Decrease clutch tension.  
• Check operational settings for  
materials being used.  
• Check paper tension.  
• Check relative moisture  
content of the paper.  
• Check roll pressures.  
• Check nip settings.  
Other Common Problems:  
Feed  
Direction  
Problem:  
Blistering in the image.  
Hints:  
• Increase speed or lower the operating  
temperature.  
Problem:  
Coiling of encapsulated images.  
Hints:  
• Balance the upper and lower unwind brake  
tension. Adjust cooling fans.  
Problem:  
Longitudinal waves or stuttering, jerking, or  
excessive noise from the drive side of the  
laminator.  
Problem:  
Waves on only one side of the  
output.  
Hints:  
Hints:  
• Increase chain tension, decrease unwind  
brake tension.  
• Check nip settings.  
• Check for even paper tension.  
• Check for proper alignment on  
initial setup.  
4-6  
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ORCA-IV Image Transfer Laminator Operation Manual  
Maintenance and Troubleshooting  
Table 4-4: Machine Troubleshooting Guide  
Problem  
Number  
Problem  
Possible Cause  
Corrective Action  
a. Is there power to the unit?  
a. Check for power to the machine  
(building circuit breaker is on,  
main switch is on (|), and the  
machine circuit breaker is on  
(up)).  
1
No display.  
a. Is the machine reset?  
a. Make sure all safety buttons are  
released (out). Be sure all kick  
cables are reset and adjusted  
properly. Press the machine reset  
(above main switch). See  
"Machine Reset Procedure" on  
page 3-3.  
2
Display reads 8888.  
a. Is the direction indicator (FWD/  
REV) pressed?  
b. Is the speed not turned up?  
a. Press FWD or REV.  
b. Turn up the speed control.  
3
4
Display reads .0 and the  
machine does not run.  
a. Is there a kick cable or safety but- a. Make sure all safety buttons are  
Display missing the decimal  
point (e.g. -reads 30 instead  
of 3.0)  
ton that has not been reset?  
released (out). Be sure all kick  
cables are reset and adjusted  
properly. Press the machine reset  
(above main switch). See  
"Machine Reset Procedure" on  
page 3-3.  
a. Is the kick cable stretched out of  
adjustment?  
a. Verify that the kick cable is truly  
resetting (listen, look). Adjust the  
kick cable. See “Adjusting the  
Kick Cable” on page 4-3.  
5
6
Display missing the decimal  
point (e.g. -reads 30 instead  
of 3.0) but the kick cables  
and safety buttons have been  
checked and the reset button  
has been pushed.  
a. Is the tension too low?  
b. Does the roll lower unevenly?  
c. Was there a misalignment on set  
up?  
d. Is there a bad roll of material?  
e. Is the web loose only when first  
starting or splicing?  
a. Increase appropriate brake ten-  
sion.  
Waiver on one side of paper/  
vinyl.  
b. Adjust cylinder flow controls.  
c. Measure from the side frame to  
the edge of material in front and  
back to verify that the material is  
webbed through straight.  
f. Is there uneven nip pressure?  
d. Try a different roll.  
e. Raise and lower the roll (pop up  
and down) to pull the initial loose  
web straight and tight.  
f. Call Technical Support to disas-  
semble and lubricate the cylinder  
lift linkage (qualified service  
technician required).  
© GBC Pro-Tech 1998 October  
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Maintenance and Troubleshooting  
ORCA-IV Image Transfer Laminator Operation Manual  
Problem  
Problem  
Number  
Possible Cause  
Corrective Action  
a. Was the initial material webbing  
straight?  
b. Is the roll telescoped?  
c. Is there excessive tension?  
a. Measure carefully from sideframe  
and straighten webbing.  
b. Use end plates on all unwinds.  
c. Lower the tension.  
7
8
Rewound material not even  
on edge.  
d. Is it a poor roll of film (soft end)? d. Try a new roll.  
a. Has the slitter idler increased in  
diameter at the point of contact  
with the blades?  
a. Sand and/or file down the higher  
Plastic slitter tube has devel-  
oped a larger diameter where  
the round knives cut causing  
paper stress lines and paper  
tearing at peal idler.  
spots in the plastic tube.  
b. Replace the slitter tube (note: use  
as little pressure on the slitter as  
possible to increase the life of the  
slitter tube).  
a. Is the rewind engaged in the  
drive?  
b. Is there air pressure?  
a. Line up the drive tang and side  
shafts over to the drive side to  
engage them.  
9
Rewind is not turning  
b. Check for appropriate main air  
supply or increase the air pressure  
to the rewind.  
a. Is the pull roll up?  
a. Lower the pull roll. The laminate  
paper rewind will not turn and the  
pressure will not increase until  
the pull roll is down.  
b. Stop the motor to allow the web  
force to be set.  
10  
11  
Laminate paper rewind will  
not turn and/or you cannot  
set the pressure.  
a. Is the IR sensor blocked?  
b. Is the IR sensor misaligned?  
c. Is there cool air blowing on the  
roll?  
a. Be sure nothing ever blocks the  
path of the IR sensor.  
b. Align the sensor.  
c. Direct the cool air away from the  
roll surface.  
Roll is overheating.  
d. Is there an electrical problem?  
d. Call Technical Support.  
4-8  
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ORCA-IV Image Transfer Laminator Operation Manual  
Maintenance and Troubleshooting  
Problem  
Number  
Problem  
Possible Cause  
Corrective Action  
a. Has a speed setting been set?  
b. Are the doors closed and shafts  
locked in?  
c. Are the e-stop buttons pressed?  
Are the kick cables reset?  
d. Is there decimal on display?  
e. Check motor fuses on the back of  
machine.  
a. Press the FWD or REV arrow and  
12  
I pressed the motor forward  
button, but the rolls would  
not turn!  
turn the speed control up.  
b. Close the doors and lock in the  
unwind/rewind shafts.  
c. Make sure all safety buttons are  
released (out). Be sure all kick  
cables are reset and adjusted  
properly. Press the machine reset  
(above main switch). See  
"Machine Reset Procedure" on  
page 3-3. Verify that the kick  
cable is truly resetting (listen,  
look). Adjust the kick cable. See  
“Adjusting the Kick Cable” on  
page 3-3.  
d. Press the machine reset (above  
main switch). See "Machine  
Reset Procedure" on page 3-3.  
e. Remove fuses and replace, if nec-  
essary. Be sure to replace with the  
correct size fuses: two 6A fuses  
for the motor and one 1A fuse for  
the power supply.  
a. see problem 12  
a. See problem 12.  
13  
14  
I pressed the motor reverse  
button, but the rolls would  
not turn!  
a. Is there air pressure to the  
machine?  
b. Is there at least 20 psi on the  
gauge?  
a. Verify that the air supply is suffi-  
cient (100 psi).  
I pressed the main roll down  
push button, but the roll did  
not go down!  
b. Turn up regulator for main roll  
pressure.  
c. Are the e-stop push buttons  
pressed and the kick cables reset?  
d. Is the machine reset?  
c. See problem 12.  
d. See problem 12.  
e. Reset the machine. See "Machine  
Reset Procedure" on page 3-3.  
a. Is there air pressure to the  
machine?  
b. Is the machine reset?  
a. Verify that the air supply is suffi-  
cient (100 psi).  
15  
16  
I pressed the main roll up  
push button, but the rolls did  
not go up!  
b. Reset the machine. See "Machine  
Reset Procedure" on page 3-3.  
a. Is there air pressure to the  
machine?  
b. Is there at least 20 psi on the  
gauge?  
c. Is the roll hook retracted?  
d. Are the e-stop push buttons  
pressed and the kick cables reset?  
e. Is the machine reset?  
a. Verify that the air supply is suffi-  
cient (100 psi).  
I pressed the pull roll down  
push button, but the rolls did  
not go down!  
b. Increase the pull roll air pressure.  
c. Disconnect and reconnect air  
pressure to the machine and  
observe pull roll locking mecha-  
nism.  
d. See problem 12.  
e. Reset the machine. See "Machine  
Reset Procedure" on page 3-3.  
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Maintenance and Troubleshooting  
ORCA-IV Image Transfer Laminator Operation Manual  
Problem  
Problem  
Number  
Possible Cause  
Corrective Action  
a. Is there air pressure to the  
machine?  
b. Is the machine reset?  
a. Verify that the air supply is suffi-  
cient (100 psi).  
17  
I pressed the pull roll up  
push button, but the rolls did  
not go up!  
b. Reset the machine. See "Machine  
Reset Procedure" on page 3-3.  
a. Are the e-stop push buttons  
a. See problem 12.  
18  
I pressed the top roll temper-  
ature control “ON” push but-  
ton and nothing happens.  
pressed and the kick cables reset? b. Reset the machine. See "Machine  
b. Is the machine reset? Reset Procedure" on page 3-3.  
c. Is there a decimal point in the dis- c. Reset the machine. See "Machine  
play?  
Reset Procedure" on page 3-3.  
a. Is the machine reset?  
a. Reset the machine. See "Machine  
Reset Procedure" on page 3-3.  
19  
20  
The display shows unusual  
numbers or characters.  
a. This is normal. This shows that  
you are in PREHEAT AUTO  
mode.  
a. If you press the preheat button  
again, it will go off.  
I press the preheater push  
button and a “P” is displayed  
on the control panel.  
a. Is the cooling fan toggle switch  
set correctly?  
a. The cooling fan push button is a  
4-way toggle switch, keep push-  
ing the button until the fan goes  
off. From the off position, press  
once to turn only the cooling idler  
on, press twice to turn the cooling  
tubes only on, press a third time  
to turn on both the cooling idler  
and the cooling tubes, and press a  
fourth time to turn the cooling  
systems off.  
21  
I pressed the cooling fan  
push button and the fan did  
not turn off.  
a. Are the e-stop push buttons  
pressed and the kick cables reset? b. Reset the machine. See "Machine  
b. Is the machine reset? Reset Procedure" on page 3-3.  
a. See problem 12.  
22  
23  
I pressed the cooling fan  
push button and the fan did  
not turn ON.  
a. Is the proximity switch that reads a. Make adjustment and try again.  
I pushed the totalizer push  
button, the display changed  
to read 4 characters, but the  
value does not increase.  
the motor sensor teeth adjusted  
properly?  
b. Does the input light “X1” come  
on when the proximity switch  
comes on?  
b. If the input light comes on, go to  
problem 48.  
a. Is the machine reset?  
a. Reset the machine. See "Machine  
Reset Procedure" on page 3-3.  
24  
I pressed the totalizer-reset  
push button while in total-  
izer mode, and it did not  
reset and other buttons on  
the panel do not work either.  
4-10  
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ORCA-IV Image Transfer Laminator Operation Manual  
Maintenance and Troubleshooting  
Problem  
Number  
Problem  
Possible Cause  
Corrective Action  
a. Is the machine reset?  
b. Is there a problem with the key-  
pad?  
a. Reset the machine. See "Machine  
25  
I pressed the totalizer-reset  
push button while in total-  
izer mode, and it did not  
reset and other buttons on  
the panel do not work either,  
but the controls on the other  
panel work.  
Reset Procedure" on page 3-3.  
b. Check/tighten the connector to  
the keypad.  
c. Is there a software problem?  
c. Call Technical Support.  
a. Has the display panel been cali-  
brated?  
b. Is the pressure transducer faulty?  
a. Call Technical Support.  
b. Call Technical Support.  
26  
My air supply is 100 psi, but  
my control panel reads less  
than 100 psi.  
a. This is a normal safety function.  
a. No corrective action necessary.  
27  
28  
When I operate the machine  
in reverse, an alarm goes off.  
a. Main rolls are down, and the rolls a. Raise the rolls or run the machine  
An alarm sounds rapidly  
after a 10 second delay.  
are not turning.  
at a slow speed to increase the life  
of the rolls.  
a. The main roll is in the up position a. If you’re not using the machine,  
29  
After 55 minutes of no activ-  
ity, a 4 beep alarm sounds,  
followed by a 30 second  
delay  
and the temperature controller is  
on.  
turn the temperature controller  
off, or lower the roll and run the  
machine at a slow speed. Failure  
to do this will reduce the life of  
your rolls and may cause perma-  
nent damage.  
a. Is there a technical problem with a. Contact Technical Support.  
the alarm?  
30  
31  
The alarm does not come on  
for the conditions outlined  
above.  
a. Are the e-stop push buttons  
a. See problem 12.  
When the rolls are stopped, I  
pressed the switch to adjust  
the pressure to the brakes or  
clutches, and nothing hap-  
pened.  
pressed and the kick cables reset? b. Reset the machine. See "Machine  
b. Is the machine reset?  
Reset Procedure" on page 3-3.  
a. This may be normal. When the  
machine is running the computer  
takes over the settings and adjusts  
the pressure to the brakes and  
clutches. The change that you  
attempted to make may have been  
too small to see on the gauge as a  
percent allowable pressure for  
that size roll.  
a. Push and release button (do not  
hold). Try manual mode.  
32  
When the rolls are moving, I  
pressed the switches to  
adjust the pressure to the  
brakes and clutches, and  
nothing happens.  
In automatic mode with the motor  
off, set the web force. When it  
starts to run, see calculated pres-  
sure sent to brake for that  
required web force. Even though  
you do not see a large increase in  
the pressure on the display, feel  
the web tension manually to see if  
the brake tension has changed.  
a. Are the shafts locked in?  
a. Close the doors and lock in the  
shafts, then try the motor.  
33  
I pressed the motor forward  
push button and the arrow  
light did not come on.  
© GBC Pro-Tech 1998 October  
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Maintenance and Troubleshooting  
ORCA-IV Image Transfer Laminator Operation Manual  
Problem  
Problem  
Number  
Possible Cause  
Corrective Action  
a. Are the guard doors closed?  
b. Is the machine reset?  
c. Are the e-stop buttons pressed  
and the kick cables reset?  
a. Close the doors.  
34  
I pressed the shaft engage  
push button and the shaft did  
not engage.  
b. Reset the machine. See "Machine  
Reset Procedure" on page 3-3.  
c. See problem 12.  
a. Has the machine blown a fuse?  
b. Did you activate the kick cable?  
a. Check fuses on the back of the  
machine.  
b. Reset the kick cable.  
35  
36  
The machine was running,  
but stopped abruptly.  
a. Was the e-stop pressed?  
b. Did you activate the kick cable?  
a. Reset the e-stop and reset the  
machine. See "Machine Reset  
Procedure" on page 3-3.  
b. Reset the kick cable and reset the  
machine. See "Machine Reset  
Procedure" on page 3-3.  
The machine was running,  
but then the rolls went up  
and the machine stopped  
a. Is the machine reset?  
a. Reset the machine. See "Machine  
Reset Procedure" on page 3-3.  
37  
38  
Nothing seems to work.  
Slitter is not cutting.  
a. Is the blade adjusted properly?  
b. Is the blade dull or damaged?  
c. Is the bushing that mounts the  
blade worn out?  
a. Check blade adjustment. “Setting  
the Slitter” on page 3-12  
b. Replace blade.  
c. Replace the bushing.  
a. Is the slitter tube enlarged?  
a. The plastic slitter tube can  
become enlarged from many cuts  
in a close area. This causes the  
edge of the paper to go around a  
larger diameter at the slitter sta-  
tion and causes small tears in the  
paper’s edges which can lead to  
the paper starting to tear all the  
way across at the rear idler. The  
solution is to sand/file down the  
frequently used raised areas on  
the slitter’s plastic tube.  
39  
Paper rips easily at the point  
it is pulled off.  
4-12  
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ORCA-IV Image Transfer Laminator Operation Manual  
Warranty  
6HFWLRQꢁꢈꢁꢃꢁ:DUUDQW\  
This warranty specifically does not cover:  
/LPLWHGꢁ:DUUDQW\  
1. Damage to the laminating rolls caused by knives,  
razor blades, other sharp objects, or failure caused  
by adhesives.  
GBC Pro-Tech Engineering Company, Inc. warrants  
the equipment sold is free from defects in material and  
workmanship for a period of one year from the date of  
delivery to the customer for parts and ninety days (90)  
from the date of delivery to the customer for labor.  
This warranty is the only warranty made by GBC Pro-  
Tech and cannot be modified or amended.  
2. Damage to the machine caused by lifting, tilting,  
and/or any attempt to position the machine other  
than rolling on the installed casters on even sur-  
faces.  
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 prod-  
uct. 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 modi-  
fication, incorrect line voltage, contaminated air  
supply, or by fire, accident, 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 period from the date of delivery.  
IMPORTANT  
Unauthorized customer alterations will void this  
warranty.  
THE WARRANTY MADE HEREIN IS IN LIEU OF  
ALL OTHER WARRANTIES, EXPRESS OR  
IMPLIED, INCLUDING ANY WARRANTY OR  
MERCHANTABILITY OR FITNESS FOR A PAR-  
TICULAR PURPOSE. GBC PRO-TECH WILL NOT  
BE LIABLE FOR PROPERTY DAMAGE OR PER-  
SONAL 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.  
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Warranty  
ORCA-IV Image Transfer Laminator Operation Manual  
Blank page.  
5-2  
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ORCA-IV Image Transfer Laminator Operation Manual  
Specifications  
6HFWLRQꢁꢉꢁꢃꢁ6SHFLILFDWLRQV  
Table 6-1: ORCA-IV Image Transfer Laminator  
Specifications  
Characteristic  
Specifications  
Dimensions  
(L x D x H)  
86" x 48" x 73"  
(2.2 x 1.2 x 1.7 m)  
Weight  
Uncrated: 3060 lbs (1814 kg)  
Main Rolls  
62" (157 cm) roll face with high  
release silicon rubber coating for  
54" wide materials  
Main Roll Open- 1.25" (3.2 cm) maximum open-  
ing  
ing  
Material  
Uses transfer materials 0 - 54"  
(0 - 137.2 cm) wide. Handles  
materials on 3" (7.6 cm) ID cores  
with material diameters up to 15"  
(38.1 cm).  
Speeds  
0 to 10 fpm (0 to 3.1 mpm)for  
transfer process with variable  
speed and 19 fpm (5.8 mpm) ,  
reversible action, start and stop  
controlled by the instrument  
panel.  
Safety Features  
All electrical and moving  
mechanical parts are located  
in bolted cabinets  
Emergency stop buttons with  
a reset button circuit  
Fully guarded with inter-  
locks  
Emergency stop kick cables  
Preheater module  
Options  
Installation  
Requirement  
230VAC 50 or 60 Hz, three  
phase, 45A per phase with pre-  
heater (35A per phase without  
preheater) for 4 wire delta  
hookup. 40A service without the  
preheater and 50A service with  
the preheater is required.  
Filtered air at 1.5 cubic feet per  
minute (cfm), 50 liters/minute at  
a pressure of 100 pounds per  
square inch (psi) (700 kPa)  
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Specifications  
ORCA-IV Image Transfer Laminator Operation Manual  
Blank page.  
6-2  
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ORCA-IV Image Transfer Laminator Operation Manual  
,
,QGH[  
Installation requirements 2-1, 6-1  
International shipments 2-5  
Isopropyl alcohol 4-1  
1XPHULFV  
3M 3-12  
$
-
Accessory pack 2-4  
Air supply 2-2  
Audible signals 3-3  
Jumper configurations 2-1  
.
Kick cable 1-2, 2-6  
Adjusting 4-3  
&
Centering the web 3-13  
Chain  
/
Lubrication 4-3  
Changing film and paper 3-14  
Cleaning 4-1  
Laminate adhesives 3-12  
Leveling 2-5  
Lubrication 4-3  
Cabinet and covers 4-2  
Doors 4-2  
0
Rolls 4-1  
Controls  
Main roll opening 6-1  
Main rolls 6-1  
Maintenance schedule 4-1  
Material 6-1  
Front brake panel 3-6  
Front control panel 3-4  
Rear brake panel 3-10  
Rear control panel 3-8  
Motor 2-7  
1
(
Nip 1-1, 1-3, 3-1  
Emergency stop buttons 1-2, 2-6, 3-2  
Environment 2-1  
2
)
Options 6-1  
Film 3-12  
3
Loading 3-11  
Paper 3-12  
Film spacing 3-14  
Front clutch/brake panel 3-6  
Front control panel 3-4  
FWD/REV switch 4-2  
Positioning the film 3-13  
Preinstallation checklist 2-1  
Process control charts 3-15  
5
*
Rear clutch/brake panel 3-10  
Rear control panel 3-8  
Recommended materials 3-12  
Reset button 1-3  
Reset procedure, machine 1-3  
Reset, machine 3-3  
Grease fittings 4-3  
+
Heater 2-7  
Controller 2-7  
Heating 3-11  
Rexam 3-12  
Riggers 1-5, 2-4  
Roll to roll transfer 3-15  
Rubber cement eraser 4-1  
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ORCA-IV Image Transfer Laminator Operation Manual  
6
Safety 1-1  
Safety features 6-1  
Safety hazard decals 1-7  
Safety information 1-1, 3-1  
Safety labels 1-5  
Setup 3-11  
Setup procedure 2-5  
Shutdown 3-16  
Shutdown, machine 3-16  
Slitter 3-12  
Specifications  
Dimensions 6-1  
Installation requirements 6-1  
Main roll opening 6-1  
Main rolls 6-1  
Material 6-1  
Options 6-1  
Speeds 6-1  
Weight 6-1  
Speeds 6-1  
Splicing  
Paper 3-14  
Vinyl 3-14  
7
Technical support  
Call 1-608-246-8844 or fax 1-608-246-8645 4-4  
8
Unpacking 2-4  
Crate 2-4  
Upper main roll 1-4  
9
Vinyl transfer 3-15  
Vinyl transfer and overlamination materials 3-12  
:
Warnings and cautions 1-1  
Warranty 5-1  
Exclusions 5-1  
7-2  
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